Gonnheimer Elektronic DC 155 User manual

User's manual
Dosing- Controller
DC 155
Manual DC155 Rev.C03
1

Page 2 1 safety guidelines DC155
Gönnheimer Elektronic GmbH phone.: [phone], fax: -41 Email: [e-mail]
Table of Contents
1 OPERATION INSTRUCTION FOR EXPLOSION PROTECTED CONTROL PANELS ................................... 3
1.1 Application and Standards............................................................................................................................................ 3
1.2 General Instructions ..................................................................................................................................................... 3
1.3 Before using the device ................................................................................................................................................ 3
1.4 Intrinsically Safe Circuits............................................................................................................................................. 3
2 INTRODUCTION: DOSING CONTROLLER DC155 .............................................................................................. 4
2.1 Short description .......................................................................................................................................................... 4
2.2 Basics ........................................................................................................................................................................... 4
2.2.1 Units for preset, sum counter and flow .......................................................................................................................................4
2.2.2 Impulse value, analog input scaling ............................................................................................................................................4
2.3 Dosing applications ...................................................................................................................................................... 5
2.3.1 Dosing control using digital solenoid valves...............................................................................................................................5
2.3.2 Dosing control with a proportional (analog) valve......................................................................................................................7
2.3.3 Flow controlled Dosing (Option PID).........................................................................................................................................8
2.3.4 Batch control with absolute level signal (requires 4...20mA analog input option ).....................................................................9
2.3.5 Forward - backward Impulse counter (requires 2 Impulse inputs option)...................................................................................9
2.4 Creep suppression......................................................................................................................................................... 9
2.5 Temperature compensation (requires Pt100- option) ................................................................................................. 10
2.6 Process monitoring..................................................................................................................................................... 11
2.6.1 Broken wire monitoring............................................................................................................................................................11
2.6.2 Flow monitoring........................................................................................................................................................................11
2.7 Safety.......................................................................................................................................................................... 12
2.7.1 Code words ...............................................................................................................................................................................12
2.7.2 Key locking...............................................................................................................................................................................13
2.8 Remote control / bus coupling.................................................................................................................................... 13
2.8.1 Remote control via digital inputs ..............................................................................................................................................13
2.8.2 TTY- interface and protocol print (Option)...............................................................................................................................13
2.8.3 Modbus (Option).......................................................................................................................................................................14
3 OPERATION MANUAL............................................................................................................................................. 15
3.1 LC-Display ................................................................................................................................................................. 15
3.2 Keyboard .................................................................................................................................................................... 16
3.3 Parameter input and Configuration ............................................................................................................................ 17
3.4 Dosing control flow chart........................................................................................................................................... 17
4 STARTING, PARAMETER DEFAULT SETTINGS............................................................................................... 19
5 RESET........................................................................................................................................................................... 20
6 POWER SUPPLY OF THE DC155............................................................................................................................ 21
6.1.1 Application inside hazardous area.............................................................................................................................................21
6.1.2 DC155 for safe area application................................................................................................................................................22
7 INSTALLATION AND CONNECTION ................................................................................................................... 22
7.1 Mounting .................................................................................................................................................................... 22
7.1.1 Panel Mounting.........................................................................................................................................................................23
7.2 Electrical Wiring ........................................................................................................................................................ 23
7.2.1 Terminal description DC155.....................................................................................................................................................24
7.2.2 Power supply.............................................................................................................................................................................25
7.2.3 Sensor terminals........................................................................................................................................................................25
7.2.4 Actor terminals .........................................................................................................................................................................26
7.2.5 TTY interface............................................................................................................................................................................27
7.2.6 RS485 interface.........................................................................................................................................................................27
8 ANNEX.......................................................................................................................................................................... 28
8.1 Block diagram DC155................................................................................................................................................ 28
8.2 Technical Details........................................................................................................................................................ 29
8.3 Transport, storage, disposal and repairs ..................................................................................................................... 29
8.4 Type Code (Configuration example).......................................................................................................................... 30
8.5 Batteries and battery replacement .............................................................................................................................. 30
8.6 Ex-technical terminal limit values.............................................................................................................................. 30
8.7 Documentation table................................................................................................................................................... 31

DC155 1 safety guidelines Page 3
Gönnheimer Elektronic GmbH phone.: [phone], fax: -41 Email: [e-mail]
!
1Operation instruction for Explosion protected control panels
1.1 Application and Standards
This instruction manual applies to explosion protected control panels of type of protection types below. This
apparatus is only to be used as defined and meets requirements of EN 60 079 particularly EN60 079-14
"electrical apparatus for potentiality explosive atmospheres". It can be used in hazardous locations which are
hazardous due to gases and vapours according to the explosion group and temperature class as stipulated on
the type label. When installing and operating the explosion protected distribution and control panels the
respective nationally valid regulations and requirements are to be observed.
1.2 General Instructions
The control panel has to have a back-up fuse as stipulated. The mains connection must have a sufficient short
circuit current to ensure safe breaking of the fuse. To achieve an impeccable and safety device operation,
please take care for adept transportation, storage and mounting, as well as accurate service and maintenance.
Operation of this device should only be implemented by authorised persons and in strict accordance with
local safety standards. The electrical data on the type label and if applicable, the "special conditions" of the
test certificate PTB 98 ATEX 2071 are to be observed.
For outdoor installation it is recommended to protect the explosion protected distribution and control panel
against direct climatic influence, e.g. with a protective roof. The maximum ambient temperature is 40°C, if
not stipulated otherwise.
1.3 Before using the device
All connections and connection points must be checked for correct cabling. Operation with damaged cables
is not permitted.
1.4 Intrinsically Safe Circuits
Erection instructions in the testing certificates of intrinsically safe apparatus are to be observed. The electrical
safety values stipulated on the type label must not be exceeded in the intrinsically safe circuit. When inter-
connecting intrinsically safe circuits it is to be tested, whether a voltage and/or current addition occurs. The
intrinsic safety of interconnected circuits is to be ensured. (EN 60079-14, section 12)
Safety Measures: to read and to comply
Work on electrical installations and apparatus in operation is generally forbidden in hazardous locations, with
the exception of intrinsically safe circuits. In special cases work can be done on non-intrinsically safe circuits,
on the condition that during the duration of such work no explosive atmosphere exists. Only explosion pro-
tected certified measuring instruments may be used to ensure that the apparatus is voltage-free. Grounding
and short circuiting may only be carried out, if there is no explosion hazard at the grounding or short circuit
connection.
Safety aspects
A batch control system built exclusively with the DC155 represents a
control system in category 1 according EN954-1. If a higher safety is
required, it is necessary to install independent working safety
facilities.

Page 4 4 manual DC155
Gönnheimer Elektronic GmbH phone.: [phone], fax: -41 Email: [e-mail]
2Introduction: Dosing controller DC155
2.1 Short description
The dosing controller DC155 is an all-purpose dosing control device to manage batch controlling of any
arbitrary liquids or solid products inside the hazardous area. Advantages of this device are:
•simply handling, an orderly key pad containing big (22 x 22 mm) keys,
•a large graphic display and a
•flexible wide functionality.
The DC155 can manage simple as well as complex dosing applications inside hazardous areas, without an
extensive wiring to a distributed control system. See advantages below:
Several Input sources
It is possible to connect any common transmitter: NAMUR or 24V digital inputs
are the standard input terminals, 4 up to 20 mA input as an option.
Temperature
compensation
The additional Pt100- input terminal allows a temperature compensation, if the
space expansion factor γof the dosing product is known and not negligible.
Intelligent dosing
features
The intelligent dosing program of the DC155 prevents shocks on the pipe system
using a continuous raise and fall ramp by the 4 up to 20 mA – proportional valve
output, as well as using a pair of fine and coarse valve.
Intelligent batch
monitoring
Furthermore, the DC155 includes a trouble alarm system to report flow disturb-
ances or sensor failures. The flow monitoring can be delayed to prevent wrong
alarm during the start and finish period of the batch.
Simply remote
control
The DC155 has several digital control inputs to realise a simple remote control
with the basic functions like “START, STOP and RESET”.
Powerful analog
output
The analog output can manage a load of 600 Ωdirectly.
PID-controlled
Dosing process
Some applications need a regulation of the flow during the batch process. The
option “regulated analog output” can manage these applications with an internal
PID- controller.
Data safety
The data is stored on an onboard non-volatile memory, if the power supply fails.
The DC155 continues at the restored state, when the mains is back.
2.2 Basics
2.2.1 Units for preset, sum counter and flow
The first step to configure the DC155 is to define the physical unit for preset, sum counter and flow. There-
fore, sufficient unit symbols are implemented into the DC155 (e.g. gram (g), kilogram (kg), tons (t), liter (l)
etc.) To define the flow several time units are available.
2.2.2 Impulse value, analog input scaling
The DC155 gets its information about the present flow via impulse or an analog signal from a flow sensor.
If it is an impulse signal, you have to define the value of one impulse to get the right amount of flow. If the
sensor signal is an analog signal, you have to define the maximum flow (e.g. 1000 kg/min) for 20 mA. The
Impulse value and analog input scaling are located in the structure menu in the input category.

DC155 4 manual Page 5
Gönnheimer Elektronic GmbH phone.: [phone], fax: -41 Email: [e-mail]
2.3 Dosing applications
Generally, a batch control system content a flow measuring, one or two valves and the batch controller.
The flow sensor measures the quantity of the product per time, which flows into the target bowl and sends
this information to the batch controller. The controller receives the flow information, integrates the flow
signal to a sum, compares the sum continuously with the preset value and controls the connected actors,
which themselves control the flow into the target bowl.
The DC155 supports many sensor signals: 24V active/passive, NAMUR, 4...20 mA (analog current signal)
and several actors. The following chapters show application examples sorted by the kind of actors.
2.3.1 Dosing control using digital solenoid valves
The most common dosing application is by using coarse and fine valves. After starting the batch process, the
fine valve opens first. When the quantity given by setpoint 1 has been reached, the coarse valve opens and a
big flow starts. Before the setpoint is reached (at setpoint value minus setpoint 2 value) the coarse valve shuts
and the remaining quantity will be added very exactly.
Additionally, it is possible to configure a lag quantity. This is the run-on quantity after both valves have been
closed.
Besides it is possible to define a maximum setpoint value, to allow only equal or smaller setpoints to be set.

Page 6 4 manual DC155
Gönnheimer Elektronic GmbH phone.: [phone], fax: -41 Email: [e-mail]
The DC155 has three free programmable digital outputs. In the example above two of them must be
reserved for valve control.
The polarity of each output can be configured as "normally open" or "normally closed".
The following figure shows any possible function of a digital output.
Figure 1 Digital output functions
Function Description (definition: output in normal open connection)
1. Counter = 0 The digital output is active, if the actual value is equal to zero. Otherwise the digital
output is inactive.
2. Fine valve Control output for a valve with a fine cross section.
Also, the control output for a single valve.
3. Coarse valve Control output for a valve with a wide cross section.
4. Dosing is running The output is active as long as the dosing is running and the pause time is not ex-
pired. Otherwise the digital output is inactive. See also the time diagram above.
5. Any failure The output is active as long as any failure (broken wire, flow to big, etc) is occur-
ring. The output remains closed until the failure has been fixed and has been
acknowledged by pressing the reset key. Otherwise the digital output is inactive.
6. Flow to small The output is active as long as the flow rate is too small and the failure is not
acknowledged. Otherwise the digital output is inactive.
7. Flow too big The output is active as long as the flow rate is too big and the failure is not
acknowledged. Otherwise the digital output is inactive.
8. Impulses The output provides one pulse for any increment of the pre-decimal place of the ac-
tual value.
Table 1: Function list of the digital outputs
The total quantity of all batch processes is added and stored by a sum counter. The sum counter is shown
permanently at the bottom of the display. The sum counter can be reset by the user manually. It provides
information about the dosed product over several batches or over a longer period of time.
Furthermore, it is possible to realise a very simple batch control using only one digital solenoid valve. In
this case you have to configure the single valve as a fine valve. Consider, the parameters like setpoint 1 and
setpoint 2 (but not the lag quantity!) lose their functions.
Select the function of
digital output 1:
0. No function
1. Counter = 0
2. Fine valve
3. Course valve
4. Dosing is running
5. Any failure
6. Flow too small
7. Flow too big
8. Impulses
. End

DC155 4 manual Page 7
Gönnheimer Elektronic GmbH phone.: [phone], fax: -41 Email: [e-mail]
2.3.2 Dosing control with a proportional (analog) valve
The DC155 can optionally get supplied with a 4...20 mA analog output to control a proportional solenoid
valve. In this case, the analog output has to be configured as "Ramp shape".
It is possible to set the maximum value of the analog output, the starting value and the ending value by using
the following three parameters (percentage values): "Limit for analog output", "Start value of the rising
ramp" and "End value of the falling ramp".
The analog output can get configured as:
0...20 mA : 0% = 0mA, 100% = 20mA
4...20 mA : 0% = 4mA, 100% = 20mA
The dosing quantity is set with the parameter "setpoint". The rising ramp is determined by the parameter
"setpoint 1", the falling ramp by "setpoint 2". The ramp is determined by the filling quantity, not by the time.
This means that the analog output is at its maximum after the quantity "Setpoint 1" has been filled and not
after a given time.
The meaning of all these parameters is demonstrated with the following diagram.

Page 8 4 manual DC155
Gönnheimer Elektronic GmbH phone.: [phone], fax: -41 Email: [e-mail]
Any alternative functions for the analog output are shown below:
Figure 2 Functions of the analog output
Function Description (definition: output in normal open connection)
1. Flow prop. signal Ratio: "actual flow / max. flow"
T
he value of "
max flow
"
is set
in the input menu
.
2. Ramp shape
C
ontrol
of
a proportional
(analog)
solenoid valve
,
s
ee working diagram above
3. Flow feedback control
O
utput of PID
flow control
ler
(
generate a
configurable flow rate
)
4.
Counter prop. signal
R
atio "
a
ctual counter value" to "setpoint"
5. Counter (max)
p
rop
.
sig
nal
Ratio "actual counter value" to "max. setpoint"
The value "
m
ax
. setpoint
" is set in the setpoints
-
menu.
6. Setpoint prop. signal
Ratio "setpoint" to "max. setpoint"
2.3.3 Flow controlled Dosing (Option PID)
Optionally, the DC155 can have an internal PID flow controller, so that the dosing can be carried out with
an adjustable flow rate. The PID parameters Kp, Ki, Kd and the flow setpoint can be configured in the pa-
rameter menu.
In the mode "Flow Feedback Control", it is possible to define a ramp similar to the uncontrolled output when
using the function "Ramp shape". There is one important difference: The ramp defined in the mode "Ramp
shape" represents the analog output value directly (100% = 20mA). The ramp in the mode "Flow Feedback
Control" refers to the PID flow setpoint. The flow setpoint represents 100%. For example, it is possible to
start the PID controller with 20% of the flow setpoint and ramp up to 100% slowly.
Q
setpoint
= Flow Setpoint
Q
actual
= Actual Flow at the time k
The sampling rate of the digital PID controller is 20ms.
Normalized error value: 








Control Signal: 

 

 





 



 




The PID parameters Kp, Ki and Kd are percentage values.
The control signal y is a percentage value, too. The value 100% corresponds to 20mA. If the analog output
range was configured to 4...20mA, 0% corresponds to the value 4mA. With an analog output range of
0...20mA, 0% corresponds to the value 0mA.
Settings for analog output:
0. No function
1. Flow prop. signal
2. Ramp shape
3. Flow feedback control
4. Counter prop. signal
5. Counter (max) prop. signal
6. Setpoint prop. signal
. End

DC155 4 manual Page 9
Gönnheimer Elektronic GmbH phone.: [phone], fax: -41 Email: [e-mail]
2.3.4 Batch control with absolute level signal (requires 4...20mA analog input option )
This kind of batch control does not work with a flow signal, but with an absolute level signal. You can either
measure the level in the container that is being filled (level rises during dosing) or the level of the container
from which the material to be dosed is removed (level falls during dosing). The valves are controlled as in
the other operating modes. Flow monitoring or displaying is not possible in this mode.
2.3.5 Forward - backward Impulse counter (requires 2 Impulse inputs option)
Some kinds of flow sensors (e. g. windmill-type anemometer) recognises back flows. These have two sensor
signals. The DC155 can determinate the flow direction using the phase relation of the two signals.
Configuration and handling of the DC155 with this option is equal to any standard application.
2.4 Creep suppression
In some applications, when using 4-20mA analog
inputs, it is necessary to suppress adding up small
flow quantities.
The figure on the right hand shows its function.
Adjust the creep suppression value in the structure
menu.
Figure 3: creep suppression

Page 10 4 manual DC155
Gönnheimer Elektronic GmbH phone.: [phone], fax: -41 Email: [e-mail]
2.5 Temperature compensation (requires Pt100- option)
Any fluid has a specific expansion coefficient γ. The volume of the fluid increases with its temperature.
Using a volume measurement sensor for a mass dosing application, introduces an inaccuracy into the dosing
process, if the temperature is not taken into account.
The DC155 can compensate the thermal expansion of a fluid according to the following formula:
!"!
#$  %"  "
&
V(ϑ) volume at actual temperature
V
0
volume at reference temperature
ϑactual fluid temperature
ϑ
0
reference temperature
γexpansion coefficient
The DC155 measures the temperature of the fluid with a Pt100 temperature sensor. The user can set the
values of the expansion coefficient and the reference temperature with the "Temperature compensation"
menu.
The signs of the temperature values are entered by using the arrow keys. The left arrow sets a negative sign,
the right arrow sets a positive sign.
The temperature measurement value can be monitored. This allows to recognise broken wires and short cuts of
the Pt100 wiring. The DC155 uses a default value, if the Pt100 temperature is outside the configured temperature
range, given by the parameters "Minimum Value" and "Maximum Value". The dosing process can either be
stopped or continued in that case. Additionally, it is possible to activate any digital output whose functionality has
been set to "Any failure".
Temperature Compensation
0. Temperature compensation: active
1. Reference temperature: 20°C
2. Coeff. of expansion: 0.100E-3 1/K
3. Temperature monitoring: Yes
4. Minimum value: -10°C
5. Maximum value: 50 °C
6. Default value: 20°C
7. Stop Dosing: Yes
8. Error signal: Yes
. End