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Presys DCY-2050 Manual

Universal process controller
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Presys
Instruments
DCY-2050 and DCY-2051 Universal Process Controller
PRESYS
LD1
LD2
A
/
M
DCY-2050
PRESYS
DCY-2051
LD1
A
/
M
LD2
TECHNICAL MANUAL

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Summary of Contents for Presys DCY-2050

  • Page 1 Presys Instruments DCY-2050 and DCY-2051 Universal Process Controller PRESYS DCY-2050 PRESYS DCY-2051 TECHNICAL MANUAL...

  • Page 2: Table Of Contents

    PRESYS | Instruments DCY-2050 and DCY-2051 Table of Contents Page 1.0 - Introduction................... 1.1 - Description................... 1.2 - Order Code Number................1.3 - Technical Specifications............... 2.0 - Installation..................... 2.1 - Mechanical Installation................. 2.2 - Electrical Installation................2.3 - Process Input Signal Connection............

  • Page 3: Introduction

    The PRESYS DCY-2050 and 2051 Controllers are microprocessor-based instruments which control and show any process variable found in industrial plants, such as: temperature, pressure, flow, level etc. The difference between models DCY-2050 and 2051 lies just in the form which process variables are shown. In model DCY-2051 the process variable is shown on a display by four larger size digits.
  • Page 4 A/M key DOWN KEY indicates, when illuminated, Fig. 1 - Controllers Front Panel DCY-2050/2051 the controllers in the manual mode and, when extinguished, the controllers in the automatic mode. In the controllers configuration modes both displays show the mnemonics and the parameter values. The...

  • Page 5: Order Code Number

    (if desired, specify such information so the whole programming may be previously prepared by Presys). Note: Any other desired software or hardware characteristics, may be available upon request.

  • Page 6: Technical Specifications

    PRESYS | Instruments DCY-2050 and DCY-2051 1.3 - Technical Specifications Inputs: Two thermocouple configurable inputs (J, K, T, E, R, S, under ITS - 90), RTD Pt - 100 under DIN 43760, 4 to 20mA, 0 to 55mVdc, 1 to 5Vdc, 0 to 10Vdc. Input impedance of 250 Ω...
  • Page 7 PRESYS | Instruments DCY-2050 and DCY-2051 Control outputs: . Analog output 4 to 20mAdc, 1 to 5Vdc, 0 to 10Vdc, use of optional cards with plug-in fitting foreseen for up to two 300 Vac modules galvanically isolated from inputs and power supply. Maximum load of 750Ω.
  • Page 8 PRESYS | Instruments DCY-2050 and DCY-2051 2-Wire Transmitter Power Supply: 24Vdc voltage and 50mA maximum, isolated from outputs, with short-circuit protection. Stability at ambient temperature: ± 0,005% per °C of span referred to an ambient temperature of 25°C. Power Supply: 90 to 240Vac Universal, (10W nominal), 24Vdc.

  • Page 9: Installation

    PRESYS | Instruments DCY-2050 and DCY-2051 2.0 - Installation 2.1 - Mechanical Installation The DCY - 2050 and 2051 controller front panels are 1/8DIN size (48 x 96mm). They are attached from the rear by two rails which push the instrument against the panel.

  • Page 10: Electrical Installation

    DCY-2050 and DCY-2051 2.2 - Electrical Installation The DCY-2050 and 2051 controllers may be powered by any voltage between 90 and 240Vac or Vdc. Note that power is always applied to the internal circuit when the instruments are connected to the AC supply.

  • Page 11: Thermocouple Connection

    PRESYS | Instruments DCY-2050 and DCY-2051 The wiring of a type of sensor in input 1, will not restrict the simultaneous use of any other sensor, whether or not of the same type, in input 2. To prevent noise induction from occurring in the sensor when connecting wire to the I/O terminal use twisted pair cable and run the sensor connection wire through a metallic tube or use a shielded cable.

  • Page 12: Rtd Connection

    PRESYS | Instruments DCY-2050 and DCY-2051 2.3.2 - RTD Connection A RTD accepts a 2-, 3-, or 4-wire connection. All connection types are shown in figure 5. In the event of a 2-wire RTD, connect the RTD between I/O terminals 1 and 3 to use input 1 or to terminals 4 and 6 to use input 2 as illustrated in figure 5.

  • Page 13: Milliampere Input

    PRESYS | Instruments DCY-2050 and DCY-2051 2.3.3 - Milliampere Input A standard 4 to 20mA current source can be applied between terminals 1(+) and 3(-) in the case of input 1, and between terminals 4(+) and 6(-) in the case of input 2;...

  • Page 14: V Or Mv Input

    PRESYS | Instruments DCY-2050 and DCY-2051 2.3.4 - Voltage Source Connection in mV or V Either a 0 to 55mVdc or a 0 to 5Vdc voltage must be applied between terminals 2(+) and 3(-) in the case of input 1 and between terminals 5(+) and 6(-) in the case of input 2.
  • Page 15 PRESYS | Instruments DCY-2050 and DCY-2051 In the case of outputs 1 and 2 we can have six types of different outputs between the current I/O terminals: current (4 to 20mA), voltage (0 to 5Vdc), voltage (0 to 10Vdc), SPST relay, open collector voltage and solid state relay.
  • Page 16 PRESYS | Instruments DCY-2050 and DCY-2051 TERMINALS FUNCTION INTERNAL DEVICE +24V OUTPUT 2 NC * Alarm SPST Logic +24V OUTPUT 3 Alarm Logic SPDT +24V OUTPUT 4 Alarm SPDT Logic (*) Relay contacts assume that SAFE condition (see section 3.2 on Configuration) was selected for relays and that the controllers are powered and in no-alarm condition.

  • Page 17: Connection Diagrams

    PRESYS | Instruments DCY-2050 and DCY-2051 2.5 - Connection Diagram Current 4-20mA Voltage 0 to 10V Transmitter Power Supply +24V COMMUNICATION RS-422/485 Tx- Tx+ Rx- Rx+ COMMOM RS-232 INPUT 2 INPUT 1 COMMOM EARTH NEUTRAl LINE OUTPUT 4 OUTPUT 3 OUTPUT 2 OUTPUT 1...

  • Page 18: Communication

    PRESYS | Instruments DCY-2050 and DCY-2051 2.6 - Communication The DCY-2050 / 2051 controllers can communicate with computers by RS-232 or RS-422/485 since optional module is installed and the communication parameters are configured. 2.7 - Engineering Units A label containing a selection of Engineering Units is supplied with each controller.

  • Page 19: Operation

    DCY-2050 and DCY-2051 3.0 - Operation 3.1 - Normal operation The DCY-2050 and 2051 controllers are provided with two operational modes: normal mode and configuration mode. In normal operation mode we can further have the automatic operation mode and the manual operation mode.
  • Page 20 PRESYS | Instruments DCY-2050 and DCY-2051 Operation Level GENERAL PASSWORD CONF GENERAL OUT 2 INPUT 2 V_OUT 2 V_OUT 2 SP 2 INPUT 2 Set-point values can be altered, both in automatic mode V_SP 2 V_SP 2 and manual mode.
  • Page 21 PRESYS | Instruments DCY-2050 and DCY-2051 The display shows 4 types of configuration for each channel. The configuration screens on the previous figure are identified by the numbers 1, 2, 3 and 4 for channel 1. Upon shifting to manual mode (green LED illuminated) the configuration screen shifts to type 3.

  • Page 22: Configuration

    PRESYS | Instruments DCY-2050 and DCY-2051 3.2 - Configuration The DCY 2050 and 2051 controllers can be configured with a password system to prevent unauthorized people from altering critical process parameters. Therefore, whenever the key ENTER is pressed, with the mnemonic CONF...
  • Page 23 (E2PROM and NVRAM) and determine the instrument normal operation. Through configuration parameters the user may adapt the instrument according to his requirements. Normally the DCY-2050 and 2051 controllers are factory configured and the user is not expected to enter the configuration mode.
  • Page 24 PRESYS | Instruments DCY-2050 and DCY-2051 Note: in the following diagrams, the controller displays are represented by rectangles in response to the selection ENTER, UP and DOWN keys T h is le v e l is v a lid o n ly fo r v e r s io n w ith c o m m u n ic a tio n .

  • Page 25: Level 1 - General

    PRESYS | Instruments DCY-2050 and DCY-2051 3.2.1 - Level 1 - General In level 1 we have the options: TAG, SOFT, PASS, INDIC, SP.Li, PO.BR, ST.CO, LED1 and LED2 (see figure 13). TAG - this option enables an alphanumeric identification for the instrument. The...
  • Page 26 PRESYS | Instruments DCY-2050 and DCY-2051 Fig. 13 - GENERAL Level Options Operation Page 24...
  • Page 27 PRESYS | Instruments DCY-2050 and DCY-2051 The adjustable parameter span shown on figure 13 is given below. Mnemonic Parameter Adjustable Span Factory Unit Value instrument 2050 identification ------------- 2051 ------------- SOFT software version ------------- C - 2.00 ------------- VALUE user password...

  • Page 28: Level 2 - Inputs

    PRESYS | Instruments DCY-2050 and DCY-2051 3.2.2 - Level 2 - Inputs The level of inputs allows whether or not to enable (by way of the option CANCEL) the sensor type for input 1 and input 2. For sensor types we have the linear option (0 to 5V, 0 to 55mV and 0 to 20mA) and temperature (option TEMP), as illustrated in figure 14.
  • Page 29 PRESYS | Instruments DCY-2050 and DCY-2051 The adjustable parameter span shown on figure 14 is given below. Mnemonic Parameter Adjustable Factory Units Value input signal associated LIM LOW to Eng Low 0.0 to 100.0 input signal associated LIM HIGH to Eng High 0.0 to 100.0...
  • Page 30 PRESYS | Instruments DCY-2050 and DCY-2051 SQRT - shows the square root of the controller input signal on the upper display. The Cut-Off parameter, expressed as a % of the input signal, forces the lower value inputs (Lim Low + Cut Off) to behave as Lim Low. See illustration on figure 16.

  • Page 31: Level 3 - Outputs

    PRESYS | Instruments DCY-2050 and DCY-2051 automatic mode, they are automatically switched to the manual mode. In this case, the output switches to the parameter defined value - PO.BR (output power level, in case of sensor failure). In the event of a burn-out with the controllers in the manual mode, they remain in the manual mode and the output should be adjusted by the operator and not by the PO.BR parameter.
  • Page 32 PRESYS | Instruments DCY-2050 and DCY-2051 The adjustable parameter span shown on figure 17 is given below. Mnemonic Parameter Adjustable Factory Units Span Value LIM LOW percentage of output full 0.0 to 100.0 scale (20 mA, 5V or 10V) defining the lowest output signal.

  • Page 33: Level 4 - Alarms

    PRESYS | Instruments DCY-2050 and DCY-2051 3.2.4 - Level 4 - Alarms In level 4 the outputs 2, 3 and 4 may be configured as alarm outputs; in this case, they are hence called relay 2, relay 3 and relay 4, respectively (see figure 19). A maximum of three alarm relays may be available through the acquisition of the corresponding option modules.
  • Page 34 PRESYS | Instruments DCY-2050 and DCY-2051 (1) SAME AS FOR RELAY 2 . (2) SAME AS FOR CA1H. (3) SAME AS FOR RELAY 2 . Fig. 19 - ALARM level options The adjustable parameter span shown on figure 19 is given below.

  • Page 35: Level 5 - Control

    DCY-2050 and DCY-2051 3.2.5 - Level 5 - Control The DCY-2050 and 2051 controllers can control up to two control loops. It is on Configuration level 5 that the desired control mode is selected for the control loops 1 and 2 (see figure 20).
  • Page 36 PRESYS | Instruments DCY-2050 and DCY-2051 (1) FOLLOW THE SAME OPTIONS AS FOR CTRL1. Fig. 20 - CONTROL Level Options Operation Page 34...
  • Page 37 (see section on Connection of control output signals) In the DCY-2050 and 2051 controllers the upper and lower displays always show the controlled variable and the set-point/output, respectively, for the control loop 1 or 2.
  • Page 38 This type of control uses two controllers. In the case of the DCY-2050 and 2051 controllers the control block 1 will act as the master controller and its output will provide the slave controller with the set-point which will be the control block 2, as illustrated on figure 23, below.
  • Page 39 PRESYS | Instruments DCY-2050 and DCY-2051 REV (reverse) - whenever REV is selected for control action (ACTION), the output signal is switched to OFF when the controlled variable exceeds the set-point value plus the hysteresis (upper limit) and switched to ON when the variable falls below the set- point minus the hysteresis (lower limit).
  • Page 40 It is used to eliminate oscillations. Note that on the DCY-2050 and 2051 controllers the deviate is applied to the controlled variable; this inhibits the derivative action whenever the set-point only is altered.
  • Page 41 PRESYS | Instruments DCY-2050 and DCY-2051 Proportional plus derivative control (P + D) The PD control, usually, leads the system to the stationary regime with less oscillations; however, the offset may still remain. Proportional plus derivative plus integrative control (P + I + D) The PID control is a solution incorporating the advantages of the PI control and the PD control.
  • Page 42 PRESYS | Instruments DCY-2050 and DCY-2051 The heating-cooling control mode is obtained by dividing the scaled output from - 100.0% to 100.0% into two portions: the cooling band (-100.0% to 0.0%) and the heating band (0.0% to 100.0%). The transition point between the two bands is 0.0%. Enabling of the heating or cooling output is dependent on the PID output computation relative to the transition point 0.0%.
  • Page 43 PRESYS | Instruments DCY-2050 and DCY-2051 Cool Gain Heat Gain Cool Integrative Rate Heat Integrative Rate Cool Derivative Heat Integrative Rate Rate -100,0% 100.0% BANT BANT OUTPUT SHOWN ON LOWER DISPLAY Fig. 26 - PID parameter variation in the heating-cooling transition...

  • Page 44: Level 6 - Tune

    3.2.6 - Level 6 - Tune The DCY-2050 and 2051 controllers can apply PID control algorithms both for control loop 1 and for control loop 2. The PID parameters: Gain (GAIN), Integrative Rate (INT) and Derivative Time (DER) are adjustable over a wide span of values in order to accommodate several processes with varying characteristics.
  • Page 45 PRESYS | Instruments DCY-2050 and DCY-2051 The auto-tune algorithm is not carried out in the ON/OFF control and in the heating-cooling control. For PID adjustment in the heating-cooling control the user should carry out the PID manual adjustment sequence described at the end of this section.
  • Page 46 PRESYS | Instruments DCY-2050 and DCY-2051 Fig. 27 - Process variable and control output for on demand auto-tune D.Out - This is the parameter determining the amplitude of the square wave generated in the control output for auto-tune computation. The control output will cause this value to vary for the more and for less from its present output.
  • Page 47 PRESYS | Instruments DCY-2050 and DCY-2051 Fig. 28 - TUNE Level Options Operation Page 45...
  • Page 48 PRESYS | Instruments DCY-2050 and DCY-2051 The adjustable parameter ranges shown on figure 29 are given below. Mnemonic Parameter Adjustable Factory Units Range Value D.Out square wave amplitude 0 to 100.0 10.0 Hyst hysteresis above and -999 to 9999 below the process variable LIM.S...

  • Page 49: Level 7 - Setp (Programmable Setpoint)

    3.2.7 - Level 7 - SetP (Programmable Setpoint) The DCY-2050 / 2051controllers can run a program which generates, repeatedly, up to ten setpoint values. The setpoint values, the time taken to reach these values and the number of times this setpoint sequence should be repeated are parameters selected by the user within Configuration level 7.
  • Page 50 PRESYS | Instruments DCY-2050 and DCY-2051 Fig. 31 - Programmable Setpoint Level Options STAT (State) - it allows the user to activate the programmable setpoint (ON), disable the programmable set-point (OFF) or to indefinitely suspend (SUSPENDED) set- point execution; in that case, the set-point value remains stationary at the set-point value which was under development when the selection SUSPENDED was assigned to parameter STAT.
  • Page 51 PRESYS | Instruments DCY-2050 and DCY-2051 The adjustable parameter ranges are shown below. Mnemonic Parameter Adjustable Factory Units Range Value COUNT counter determining how 1 to 250 repeats many set-point cycles will be executed or how many cycles are left before the end of the programmable set-point execution.

  • Page 52: Level 8 Calibration

    PRESYS | Instruments DCY-2050 and DCY-2051 3.2.8 - Level 8 Calibration Level 8 is described in section 4.4 on Calibration. 3.2.9 - Level 9 - RS Refer to the communication manual. Operation Page 50...

  • Page 53: Maintenance

    PRESYS | Instruments DCY-2050 and DCY-2051 4.0 - Maintenance 4.1 - Controllers Hardware Controllers maintenance requires the user to have access to the instrument hardware. The controller hardware is divided into three main circuit boards: the Display Circuit Board, the CPU Circuit Board and the Power Source Circuit Board. The three circuit boards are attached to the aluminum case by only one screw located at the front panel.

  • Page 54: Hardware Configuration

    PRESYS | Instruments DCY-2050 and DCY-2051 4.2 - Hardware Configuration The input level configuration by software (level 2 - Inputs) should be implemented by a process input configuration by hardware, by way of internal jumpers. There are four places for the installation of jumpers for channel 1: J5, J6, J7 and J8;...

  • Page 55: Snubber Use For Relay

    PRESYS | Instruments DCY-2050 and DCY-2051 (*) In the case of input under a voltage from 0 to 10V the second factory supplied jumper should be stored by the user away from the instrument or simply engaged to one of the connector pins, in a dummy position as illustrated on figure 34.
  • Page 56 DCY-2050 and DCY-2051 4.4 - Optional Module Connections The DCY-2050 and 2051 controllers may be provided with up to four output signals plus communication. For that purpose, the corresponding optional modules should be installed inside the instrument. By opening the controllers as explained in section 4.1, access is gained to 4 plug-in connections on the Power Source Board, plus...
  • Page 57 PRESYS | Instruments DCY-2050 and DCY-2051 Outputs 1 and 2 as analog outputs (optional module code: MSAN-20) Whenever output 1 is required to be the analog output (4 to 20mA, 1 to 5V or 0 to 10V) the optional module is plugged in the connection called MOD 1. In case an additional analog output is required, a second module is plugged in the connection called MOD 2.

  • Page 58: Calibration

    Table 5 - Logic output type for outputs 3 and 4 4.4 - Calibration The DCY-2050 and 2051 controllers are accurately calibrated at factory and will not require periodic recalibration under normal conditions. If, for any reason, a recalibration is required, follow the procedure described below.
  • Page 59 PRESYS | Instruments DCY-2050 and DCY-2051 While the display is flashing, the reference should remain connected to the input channel to be calibrated. When the display stops flashing and the corresponding mnemonic is back on screen, the calibration process for the first point will have ended.
  • Page 60 PRESYS | Instruments DCY-2050 and DCY-2051 Voltage Input Calibration (0 to 55mV) In order to calibrate the voltage input at 0 to 55mV connect an accurate DC power source to the channel to be calibrated (terminals 2(+) and 3(-) for channel 1 or 5(+) and 6(-) for channel 2).
  • Page 61 PRESYS | Instruments DCY-2050 and DCY-2051 Calibration of current input (0 to 20mA) In order to calibrate the current input at 0 to 20mA connect an accurate DC power source to the channel to be calibrated (terminals 1(+) and 3(-) for channel 1 or 4(+) and 6(-) for channel 2).
  • Page 62 PRESYS | Instruments DCY-2050 and DCY-2051 For output calibration follow the procedure described to calibrate the analog outputs 1 and 2. The analog outputs will be calibrated by the controllers themselves. Output 1 will be calibrated by input 1 and output 2 will be calibrated by input 2.

  • Page 63: Hardware Maintenance Guidelines

    PRESYS | Instruments DCY-2050 and DCY-2051 Reverting to factory calibration The controllers store the factory calibration parameters in the non-volatile memory and these can be retrieved at any time. Should there be any suspicion that some instrument malfunction might be due to an improper recalibration procedure use the RECUP option (see figure 38).
  • Page 64 PRESYS | Instruments DCY-2050 and DCY-2051 Instrument malfunction Check that the controllers are correctly configured both in terms of software and hardware (internal jumpers). Check that the option modules are fully engaged in their correct locations. Measure the voltage at flat-cable 1 as shown on figure 39 to see if they are close to the voltages in table 12 and arriving at the CPU end.

  • Page 65: Parts Listing

    PRESYS | Instruments DCY-2050 and DCY-2051 4.7 - Parts Listing Display Circuit Board Code Components Reference 01.05.0051-20 Display circuit board - DCY 2050 --------------------- 01.05.0054-20 Display circuit board - DCY 2051 01.07.0003-21 Display 14mm DP1,2,3,4,5,6,7,8 (2050) DP5,6,7,8 (2051) 01.07.0002-21 Display 17mm...
  • Page 66 PRESYS | Instruments DCY-2050 and DCY-2051 01.02.0113-21 Resistor 47K 01.02.0114-21 Resistor 270R 01.02.0115-21 Resistor 4R7 01.02.0116-21 Resistor 18K 01.02.0054-21 Resistor 150K 01.06.0003-21 Transformer 01.06.0004-21 Coil 01.13.0004-21 Connector CN1,2,3,4,5,6,7,8 CPU Circuit Board Code Components Reference 01.05.0048-20 CPU Circuit Board - DMY2030 ----------------------- 01.01.0007-21...
  • Page 67 PRESYS | Instruments DCY-2050 and DCY-2051 01.02.0024-21 Resistor Maintenance Page 65...
  • Page 68 PRESYS | Instruments DCY-2050 and DCY-2051 01.02.0031-21 Resistor 4K99 R7,8,9 01.17.0002-21 Jumper Selected 01.17.0003-21 Pin bar J1-J4 J5-J8 01.18.0001-21 Receptacle 01.13.0005-21 Connector CN1,CN2 01.14.0006-21 Flat-Cable 12 ways 01.14.0007-21 Flat Cable 14 ways 01.14.0008-21 Flat Cable 15 ways I/O Terminal Board...
  • Page 69 PRESYS | Instruments DCY-2050 and DCY-2051 01.04.0010-21 Zener BZX 79/C5V6 01.04.0005-21 Reference diode LM 336 / 5.0 V 01.03.0037-21 Polyester capacitor 0.1 uF X 100 V 01.03.0046-21 Polyester capacitor 0.22 uF X 100 V 01.03.0042-21 Radial electrolytic capacitor 22 uF X 25 V 01.02.0038-21...

  • Page 70: Recommended Spare Parts Listing

    PRESYS | Instruments DCY-2050 and DCY-2051 4.7 - Recommended Spare Parts Listing Display Board Display DP1, 2, 3, 4, 5, 6, 7, 8 I/O Power Board IRF 822 UC 3842 Fuse 1A LM 1458N I/O Terminal Board AD 592 CPU Board...
  • Page 71 PRESYS INSTRUMENTOS E SISTEMAS LTDA. RUA LUIZ DA COSTA RAMOS, 260 - SAUDE SAO PAULO SP BRAZIL 9001 04157-020 - PHONE +55 (11) 5073.1900 - FAX +55 (11) 5073.3366...

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