User`s Manual - MBH Engineering Systems
Contents
1. User s Manual FI um BR Song DR 5000 Circle Chart Recorder fd FuTUREDESIGN Warning Symbol A This A Symbol calls attention to an operating procedure practice or the like which if not correctly performed or adhered to could result in personal injury or damage to or destruction of part or all of the product and system Do NOT proceed beyond a warning symbol until the indicated conditions are fully understood and met Use the Manual Installers Read Chapter 1 2 3 e System Read All Chapters NOTE Itis strongly recommended that a process should incorporate a LIMIT like Future Design s L91 which will shut down the equipment at a preset process condition in order to preclude possible damage to products or system Information in this user s manual is subject to change without notice Copyright May 2003 Future Design Controls all rights reserved No part of this publication may be reproduced transmitted transcribed or stored in a retrieval system or translated into any language in any form by any means without the written permission of Future Design Controls UM DR5000 Rev 1 5 2003 Contents DR5000 Recorder Page Number Chapter1 Overview 1 1 General 1 2 Ordering Code c AR Chapter 2 Installation 2 1 Unpacking 6 2 2 Mounting 6 2 3 Case Location 7 2 4 Wiring Precautions 8 2 5 Power Wiring 9 2 6 Sensor Installation Guidelines 10 2 7 Thermocouple Input Wiring 11 2 8 RTD Input Wiring 12 2 92. CHART P N R18 270 for CCW or P N R18 272 for CW rotation This chart contains the configuration categories of the recorder Probe Input Inner Chart Values Outer Chart Values Units Chart Rotation Input Averaging and Relay Options Place the SET UP CHART onto the recorder This setup chart should be saved for future reference once setup complete 1 Place SETUP CHART on recorder P N R18 270 for CCW and P N R18 272 for CW 2 Press and release CHANGE CHART key 3 3 Wait until pen moves above scale and green LED stops flashing 4 Press and hold LEFT arrow key 1 until LED goes off then release key 5 Pen will move to outer ring of chart Wait for LED to flash slowly 8sec on 8 sec off LED will continue to flash slowly during setup 6 Loosen Chart knob and rotate chart to position RED pen in the middle of the START CIRCLE 7 Tighten chart knob Press and release the CHANGE CHART key 3 Pen will move to PROBE INPUT column on the setup chart 8 Position pen to the desired selection using LEFT 1 and RIGHT 2 keys 9 Press and release CHANGE CHART key 3 to store selection and advance to next category 10 Repeat selection process until all categories are selected You must Press and release CHANGE CHART key 3 after last category 11 After all categories are selected pen will move off scale and LED will Stop flashing Steady on 12 Remove SETUP CHART and save Install actual recording chart 13 Press a
3. Otherwise this pen offset can cause the unit to record an incorrect temperature on the chart CHANGE CHART Figure 4 1 Keypad UM DR5000 Rev 1 5 2003 4 2 Ink Style Probe Offset Adjust Pen Offset This recorder has been accurately calibrated at the factory Before making any adjustments this instrument should be in service for 24 hours Thereafter if any adjustment is required perform the following procedure 1 Place a Certified Test Thermometer s alongside the recorder s sensor probe s in a monitored controlled condition Once the temperature has leveled out compare the position of the pen on the recorder to the test thermometer s reading also compare the Certified Test Thermometer s reading to the second pen of the recorder If an adjustment is required for a single pen unit depress and hold either the LEFT 1 or RIGHT 2 arrow key The pen will begin to move after approximately ten 10 seconds Using the LEFT arrow 1 or RIGHT 2 arrow keys position the pen on the chart to correspond to the temperature of the Certified Thermometer Once the corrected value is obtained no further keystrokes are required For two 2 pen ink recorders you must first select the pen that you wish to calibrate This is done by pressing the LEFT 1 arrow key to select the Red pen or the RIGHT 2 arrow key to select the Blue pen The appropriate arrow key must be held down for approximately five 5 seconds after which the g
4. S N and date code D C are labeled on the box and the bottom side of the recorder Make sure that all items are accounted for 1 Battery for optional battery backup 2 Ferrite Bead 3 Installation manual 2 2 Mounting Make panel cutout to dimension shown in Figure 2 1 UM DR5000 Rev 1 5 2003 Install both mounting clamps and insert the case into panel cutout 11 i I RN Es oa Ag i 14 FLUSH MOUNTED PANEL CUT OUT DIMENSIONS Og 9 hg 27 Figure 2 1 Mounting Diagram 2 3 Case Location Upon unpacking find a suitable location to mount the recorder before wiring power to the unit After the recorder has been connected to the main AC power supply connect the battery optional to the battery strap and place the battery in it s holder Select a location that is well lighted free from dust dirt or corrosive fumes The instrument should not be located near any sources of heat or be subject ot sudden or extreme temperature changes It should be mounted on a rigid support that is not subject ot vibration Refer to figure 2 1 for recorder case dimensions UM DR5000 Rev 1 5 2003 2 4 Wiring Precautions Before wiring verify the label for correct model number and options Switch off the power when checking Care must be taken to ensure that maximum voltage rating specified on the label are not exceeded It is recommended that power of these units to be protected by fuses or circu
5. Future Design s option is limited to replacement or repair free of charge or refund of purchase price within the warranty period specified This warranty does not apply to damage resulting from transportation alteration misuse or abuse RETURNS No product cab be return without a completed Return Material Authorization RMA form Please contact Future Design Controls for an authorization number UM DR5000 Rev 1 5 2003 Chapter 8 Spare Parts Red Pens P N R25 2 Blue Pens P N R25 3 Ink Pen Blades CCW P N R13 9 04 Ink Pen Blades CW P N R13 9 05 Thermal PrintArm Assembly P N R27 76 Setup Charts Ink CCW P N R18 270 Setup Charts Ink CW P N R18 272 Setup Charts Thermal P N R18 271 Standard Charts Blank Thermal Charts 50 box P N 00218001 UM DR5000 Rev 1 5 2003 DR 5000 Circle Chart Recorder 524 West 98th Place Bridgeview IL 60455 Phone 888 51 5444 Fax 888 307 8014 UM DR5000 Rev 1 5 2003
6. Linear DC Input Wiring 12 2 10 Alarm Relays 13 2 11 Changing the Chart 14 2 12 Marking Systems 14 2 13 Replacement of Pen Ink Style 15 2 13 1 Replacement of Thermal Head 16 2 14 Battery Backup 17 Chapter3 Programming 3 1 Recorder Setup 3 1 1 Single Pen Ink 18 3 1 2 Dual Pen OEM Ink 19 3 1 3 Dual Pen Universal Input InR 20 3 1 4 Thermal Recorder 21 3 2 Alarm Settings 22 3 2 1 Ink Style 22 3 2 2 Thermal Style 23 Chapter 4 Calibration 4 1 Pen Zero and Span Ink Style 24 4 2 Probe Offset Ink Style 25 4 3 Probe Offset Thermal Style 26 Chapter 5 Specifications 27 Chapter 6 Defaults Glossary 29 Chapter 7 Troubleshooting 29 Chapter 8 Spare Parts 31 UM DR5000 Rev 1 5 2003 Chapter 1 Overview 1 1 General The DR 5000 is a microprocessor based circle chart recorder Programmable alarm options combined with ease of setup provide the flexibility reguired for multiple recording applications This manual will cover both ink type and thermal print versions The DR 5000 is the first recorder to self document setup configuration during initial setup and can operate using standard or competitive charts The battery backup option on ink type units provides up to 48 hours of recording in the event of power loss thereby providing an additional degree of protection for customer processes A green LED indicates battery condition see section 2 14 The Thermal print version offers a single chart inventory for all recording needs Print y
7. own outer inner ring calibration is not necessary To check and or adjust the recording pen s calibration to the inner and outer graduations of the chart on ink type units Perform the following 1 Remove power to instrument If unit has battery option also remove battery 2 With all power removed press and hold the CHANGE CHART key 3 While holding the CHANGE CHART key 3 re apply power Release key upon applying power either AC or battery which ever is convenient 3 The pen s will move off scale LED will flash rapidly Green LED will Then go to on steady If 1 pen ink unit go to step 5 next 4 The blue pen will then move to 100 ring Adjust blue pen if necessary using LEFT 1 and RIGHT 2 keys to position pen on 100 ring then Wait 5 Red pen will then move to 100 ring Adjust this pen if necessary to 100 ring using LEFT 1 and RIGHT 2 keys then wait 6 Red pen will then move to 0 ring Adjust pen using LEFT 1 and RIGHT 2 keys then wait Pen will then move full upscale If 1 pen unit go to step 8 7 Blue pen will move to 0 ring Adjust pen to 0 using LEFT 1 and RIGHT 2 keys then wait Blue pen will now travel full upscale 8 Pen s calibration is now complete Pen s will then go directly to actual recording values Each time the chart paper or fiber tip pen cartridge is changed you should make sure that each pen stops at the inner and outer most temperature graduation of the chart paper
8. provided that the three leads are of same gauge and egual length Two wire RTD should be avoided if possible for the purpose of accuracy A 0 4 ohm lead resistance of a two wire RTD will produce 1 degree C temperature error 2 9 Linear DC Input Wiring Pen 1 Pen 2 DC linear voltage and linear current connections are also shown in the previous input wiring figures 2 10 Alarm Relays If your recorder has the optional relay contacts installed then terminal blocks J1 and J2 have been provided for connection to the relay on the microprocessor PC board of the recorder Refer to Figure 2 4 for Single Pen Units Refer to Figure 2 6 for Dual Pen Ink and Thermal Units NOTE OEM unit has no Alarm relay outputs A CAUTION DO NOT TOUCH the terminals of the transformer while the recorder is connected to the main AC power supply To avoid the risk of possible electric shock unplug or disconnect the recorder from the main power supply before attempting to access the terminals of the relay If the recorder is installed with the battery back up option disconnect the 9 Volt battery to avoid damaging the recorder and draining the battery Your recorder will have a hinged chart plate held in place by two 2 screws located on the right hand side of the chart plate Remove these two screws and open the hinged chart plate If you are not sure how to access the back of the chart plate please contact FUTURE DESIGN CONTROLS before continuing The
9. relays are rated for the follovving maximum Values 2 0 AMPS at 25VDC 1 0 AMP at 120VAC VVarning Damage to the recorder may result if the ratings for the relays are exceeded UM DR5000 Rev 1 5 2003 2 11 Changing the Chart Press and release the CHANGE CHART key 3 on Figure 2 7 The pen s will move to the left of the chart and green LED will flash rapidly Wait until the pen s stops above outer ring AND green LED goes to on steady Unscrew the chart hub knob at the center of the chart Remove the old chart paper and position the new one so that the correct time line coincides with the time line groove on the chart plate Refer to Figure 2 10 Page 17 for the location of the time line groove Re attach the chart hub knob and screw securely by hand against the chart Press and release the CHANGE CHART key 3 The pen s will move to the outer ring then pause The green LED will remain on Pen s will then go to current recording value Check to make sure that the pen s is marking on the chart paper If it is not then carefully adjust the pen arm to establish contact with the paper On a thermal print recorder the thermal stylus does not need adjustment 2 12 Marking Systems Ink Type Pens This type of pen consists of a self contained ink reservoir with a porous plastic stylus which is snapped around the outer edge of the metal pen arm A pen cap is provided to extend the life of the ink pen during shipping or whe
10. the reverse order of disassembly 8 Reconnect AC power to unit Pen will align itself and begin normal recording Platen Front View Platen Rear View Stylus Screws Thermal Stylus rd Thermal Print Head Leads Thermal Print Head Mother Board Platen Screws Figure 2 9 Thermal Recorder Platen Layout UM DR5000 Rev 1 5 2003 2 14 Battery Backup Ink Style Units Having the optional 9 volt DC battery back up in place will allow the recorder to continue to function normally for approximately 48 hours in the event of a power failure The green LED assists in indicating battery condition When a recorder has this option feature If green LED is on continuous battery voltage is acceptable If green LED is flashing rapidly battery voltage is below 7 5 VDC replace battery If green LED is not on battery voltage is insufficient and AC power off The battery strap and battery holder are located on the front of the chart plate refer to Figure 2 10 In order to change the battery you must open the recorder case door Note Use only NEW 9 volt alkaline replacement batteries BATTERY ma STRAP BATTERY HOLDER Green LED CHART HUB CHAIN TIME LINE GROOVE CHART PAPER CHART PLATE Figure 2 10 Recorder Platen Layout Battery Installation UM DR5000 Rev 1 5 2003 Chapter 3 Programming 3 1 1 Recorder Setup Single Pen Ink Type In order to configure the recorder you will need the recorder SET UP
11. CHART key 3 Pen will move to PROBE INPUT column on the setup chart 8 Position pen to the desired selection using LEFT 1 and RIGHT 2 keys 9 Press and release CHANGE CHART key 3 to store selection and advance to next category 10 Repeat selection process until all categories are selected You must Press and release CHANGE CHART key 3 after last category 11 After all categories are selected pen will move off scale and LED will Stop flashing Steady on 12 Remove SETUP CHART and save Install actual recording chart Recording Chart Part number 00218001 13 Press and release CHANGE CHART key 3 14 The thermal stylus will now begin printing the chart The thermal stylus will print all scales date time and trend lines automatically DU M o UM DR5000 Rev 1 5 2003 3 2 1 Alarm Settings Ink Style Recorders Alarm setpoint values are selected by positioning the pen to the actual value on the recording chart Alarm settings can be selected or viewed after CHART CHANGE recorder setup or during initial power up To set the alarm setpoint during normal recording operation complete the following steps Press and release the CHANGE CHART key 3 on Figure 3 2 Wait until pen s moves off scale and LED status changes from flashing to steady Press and release the CHANGE CHART 3 again the pen will begin to move back onto the chart briefly stopping at or close to the outermost graduation of the chart Green LED remains on st
12. Latching Error Protection De energized during sensor break Hysteresis Set at 2 units activation is safe sided Battery Back up Ink Style Up to 48 hours of recording optional Thermal Print Style Maintains real time clock Environmental and Physical Operating Temperature 0 to 60 C Storage Temperature 40 to 65 C Humidity 0 90 RH non condensing Agency Approvals UL CUL File E232762 CSA File Installation Category Il Pollution Degree 2 Altitude 2000 meters Vibration 0 3 to 100Hz 0 2g Mounting 20 degrees of vertical 10 degrees of horizontal Moldings Fire retardant Noryl w acrylic window Panel Rating Nema 12X std Nema 4 optional Dimensions 14 00 H x 14 00 W x 3 80 D Panel Cutout Industry Standard 12 70 x 12 70 Weight 7 pounds maximum UM DR5000 Rev 1 5 2003 5 1 Input Range Table Color elo a 130 C 760 C White 202 F 1400 F Red 13G C 1370 C Yellow 202 F 2498 F Red 200 C 400 C Blue 328 F 752 F Red 100 C 1824 C Gray 212 F 3315 F Red J K T E 0 C 1650 C Black oF 3002 F Red E S 0 C 1649 C Black 32 F 3000 F Red PTIOO 210 C 440 C DIN 346 F 824 F AMA 20mA OV 5VDC Table 5 1 Input Characteristics Lower Chart Range Selection Programmable from 999 to 9999 Units Upper Chart Range Selection Programmable from 999 to 9999 Units Table 5 2 Upper Lower Chart Ranges Not
13. SETUP CHART first Then Red pen will then move to outer ring Please note Blue pen will remain at outer ring of chart during setup Pen 2 is fixed for 0 100 for analog input Loosen chart knob and rotate chart to position Red pen in middle of the START CIRCLE Tighten chart knob Press and release the CHANGE CHART key 3 Red Pen will move to first selection category to current value Position red pen to desired selection using LEFT 1 and RIGHT 2 keys Press and release the CHANGE CHART key 3 to store selection Repeat selection process in EACH category until all categories are Selected After last category Relay is selected this setting should be set to DISABLED press and release CHANGE CHART key 3 Pens will move off scale Green LED will flash rapidly Wait until Green LED goes to on steady Setup is now complete Remove and store SETUP CHART Install actual recording chart to be used Press and release CHANGE CHART 3 key Pens will move to 100 ring Then to actual recording values UM DR5000 Rev 1 5 2003 3 1 3 Setup Of Dual Pen Universal Ink Style In order to configure the recorder you will need the recorder SET UP CHART P N R18 270 for CCW or P N R18 272 for CW rotation Universal Inputs allow the user to select a different type of input for each pen The setup chart contains the configuration categories of the recorder Probe Input Inner Chart Values Outer Chart Values Units Chart Rotation Input Aver
14. age is low Action Replace battery If option is applicable 4 LED flashing RAPIDLY and pen s at 0 or 100 ring indicates that input sensor s are in a break condition Action Check or replace sensor validate setup information for sensor 5 LED flashing slowly 8 sec On 8 sec off unit in setup mode Action Complete setup procedure of recorder Or performing Probe offset procedure 6 LED not on indicates no power to unit Action Check to see if AC present on power terminals If battery option exists check and or replace battery UM DR5000 Rev 1 5 2003 Warranty Future Design Controls warranties or representations of any sort regarding the fitness for use or the application of its products by the Purchaser The selection application or use of Future Design products is the Purchaser s responsibility No claims will be allowed for any damages or losses whether direct indirect incidental special or conseguential Specifications are subject to change without notice In addition Future Design reserves the right to make changes without notification to Purchaser to materials or processing that do not affect compliance with any applicable specification Future Design products are warranted to be free from defects in material and workmanship for one year after delivery to the first purchaser for use An extended period is available with extra cost upon request Future Design s sole responsibility under this warranty at
15. aging and Relay Options Place the SET UP CHART onto the recorder This setup chart should be saved for future reference once setup complete 1 Place SETUP CHART on recorder P N R18 270 for CCW or P N R18 272 for CW 2 Press and release CHANGE CHART key 3 3 Wait until pens moves above scale and green LED stops flashing 4 Press and hold LEFT arrow key 1 until LED goes off then release key 5 Blue Pen will move to outer ring of SETUP CHART Red pen will then move to outer ring Please note Blue pen setup selections allowed are categories Input Probe and Relay selections only Wait for LED to flash slowly 8sec on 8 sec off LED will continue to flash slowly during setup 6 Loosen Chart knob and rotate chart to position RED pen in the middle of the START CIRCLE 7 Tighten chart knob Press and release the CHANGE CHART key 3 Pen will move to PROBE INPUT column on the setup chart 8 Position pen to the desired selection using LEFT 1 and RIGHT 2 keys 9 Press and release CHANGE CHART key 3 to store selection and advance to next category 10 Repeat selection process until all categories are selected You must Press and release CHANGE CHART key 3 after last category 11 After all categories are selected pen will move off scale and LED will Stop flashing Steady on 12 Remove SETUP CHART and save Install actual recording chart 13 Press and release CHANGE CHART key 3 14 LED will remain on steady p
16. ays Recording style 1 and 2 only allow 1 relay per pen Ink Recorders ONLY Allows 48 hours of continuous recording upon power loss UM DR5000 Rev 1 5 2003 Chapter 2 Installation A Dangerous voltages capable of causing death are sometimes present when wiring the instrument Before installation or beginning any troubleshooting procedures the power to all eguipment must be switched off and isolated Units suspected of being at fault must be disconnected and removed to a properly eguipped workshop for testing and repair Component replacement and internal adjustments must be made by gualified personnel only This recorder operates on 110 or 220 50 60hz be sure line voltage is OFF before connecting recorder D This symbol represents Earth Ground connection A To minimize the possibility of fire or shock hazards do not expose this instrument to rain or excessive moisture A Do not use this instrument in areas under hazardous conditions such as excessive shock vibration dirt moisture corrosive gases or oil The ambient temperature of the areas should not exceed the maximum rating specified in Chapter 5 2 1 Unpacking Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage If any damage due to transit report and claim with the carrier Write down the model number serial number and date code for future reference when corresponding with our service center The serial number
17. ck up See drawing below for correct installation of this device Figure 2 3 Q Sensor wire in mm NM Ferrite Bead j Sensor wire out to Input terminal Figure 2 3 A CAUTIONI DO NOT TOUCH the terminals of the transformer while the recorder is connected to the main AC power supply To avoid the risk of possible electric shock unplug or disconnect the recorder from the main power supply before attempting to open the recorder If the recorder is installed with the battery back up option disconnect the 9 Volt battery to avoid damaging the recorder and draining the battery Your recorder will have a hinged chart plate held in place by two 2 screws located on the right hand side of the chart plate Remove these two screws and open the hinged chart plate If you are not sure how to access the back of the chart plate please contact FUTURE DESIGN CONTROLS before continuing UM DR5000 Rev 1 5 2003 2 7 Thermocouple Input Wiring Thermocouple input connections are shown in the following figures The correct type of thermocouple extension lead wire or compensating cable must be used for the entire distance between the unit and the thermocouple ensuring that the correct polarity is observed throughout Splices in the cable should be avoided if possible A Ferrite bead is supplied with the DR5000 recorder to provide additional isolation against input noise Input wiring should be wrapped around the core before wiring to the recorder input
18. e Recommended minimum chart span for thermocouple inputs is 100 UM DR5000 Rev 1 5 2003 Chapter 6 Default Settings Glossary FACTORY SET DEFAULTS Defaults settings are identical for 1 and 2 pen ink or thermal recorders Input JT C Unit Fahrenheit Scale 0 100 Rotation 24 hour Input Aver 4 Optional alarms when ordered Alarms High ALarm Setpoint 90 F Input for pen 2 on OEM recorder is defaulted to 4 20 ma scaled 0 100 GLOSSARY Input Averaging The number of input readings in seconds held and averaged as pen is recording The larger the number the more pen response is dampened High Alarm Output relay energized when process variable above set value Low Alarm Output relay energized when process variable below set value Band Alarm Output relay is energized when process variable is above high set value or below low set value Latching Output relay requires a Reset depress 3 key to de energize relay after activating Note Reset occurs regardless of alarm condition Chapter 7 Troubleshooting GREEN LED LIGHT SEQUENCE GUIDE 1 LED on steady and pen s within chart range unit is recording normally 2 LED on steady and pen s above 100 ring indicates unit is in CHART CHANGE mode Action Press and release CHART CHANGE key to return to normal recording mode 3 LED flashing RAPIDLY and pen s within chart range indicates battery volt
19. eady during this time Single Alarm Setting After the above operation is complete the active pen s arm will move to the current alarm setpoint position on the chart one pen at a time The green LED will go out during this time the alarm setpoint for each pen can be adjusted using the LEFT arrow 1 or the RIGHT arrow 2 keys on the keypad Once the alarm setpoint is set wait for the green LED will turn on and the pen arm will move to indicate the probe s temperature and the unit will begin normal recording operation Band Alarm Setting When programming the recorder for band alarm operation the active pen s will move to the first band setpoint on the chart The green LED will go out The alarm band 1 setpoint can now be adjusted using the LEFT arrow 1 or the RIGHT arrow 2 keys once set wait for the green LED to turn on The active pen will then move to the second band alarm setpoint The green LED will go out The alarm band 2 can now be adjusted When pen s alarm setpoints adjustments are completed wait for the green LED to turn on and the pen arm will move to indicate the probe s temperature and the unit will begin normal recording operation The Change Chart key is the RESET when the recorder is programmed for latching alarm operation NOTE Alarm reset occurs upon depressing Change Chart 3 key regardless of alarm condition CHANGE CHART Figure 3 2 Keypad Layout UM DR5000 Rev 1 5 2003 3 2 2 Alarm Settin
20. ed to the metal pen arm using a special U clip tab For ease of replacement it is suggested that the two 2 screws that hold the pen arm be loosened and the pen cartridge and metal pen arm be removed as an assembly Refer to Figure 2 10 page 17 for the location of the pen arm screws Unsnap the plastic U clip tab of the pen cartridge from the metal pen arm remove and discard the old pen cartridge Replace the new cartridge by opening the hinge and snapping it securely around the metal pen arm Refer to Figure 2 8 for pen cartridge replacement PEN CAP Ed J CLIP TAB PEN CARTRIDGE Figure 2 8 Pen Replacement UM DR5000 Rev 1 5 2003 2 13 1 Replacement of Thermal Stylus The thermal print head is securely fastened to the metal stylus arm which is attached to the pen motor drive assembly For ease of replacement it is suggested that the stylus with print head attached be removed as a complete assembly 1 Disconnect AC power from unit 2 Remove the two platen screws located on the front of the platen at the right center of the platen 3 Follow the thermal pen leads to the main mother board located on the back of the recorder platen 4 Remove the plug in thermal print head leads from the main mother board 5 Remove the pen arm screws that attach the pen arm stylus to the pen arm motor assembly located on the front of the platen 6 Remove the pen arm assembly 7 Install new pen arm assembly in
21. en will stop at 100 ring then to alarm setpoint values if enabled LED will turn off when pen s reaches alarm setpoint Use RIGHT LEFT arrow keys to adjust alarm value s for pen LED is on steady when pen s are recording actual values UM DR5000 Rev 1 5 2003 3 1 4 Setup Of Thermal Recorders In order to configure the recorder you will need the recorder SET UP CHART P N R18 271 Thermal print recorders use a single thermal printhead for single and two channel units The setup chart contains the configuration categories of the recorder Probe Input Inner Chart Values Outer Chart Values Units Chart Rotation Input Averaging and Relay Options Place the SET UP CHART onto the recorder This setup chart should be saved for future reference once setup complete Place SETUP CHART on recorder P N R18 271 Press and release CHANGE CHART key 3 Wait until stylus moves to top of chart and green LED stops flashing Press and hold LEFT arrow key 1 until LED goes off then release key Thermal stylus will move to outer ring of setup chart The left and right arrow keys can be used to adjust the center line on the print head to the outer ring of the setup chart at this time Wait for LED to flash slowly 8sec on 8 sec off LED will continue to flash slowly during setup 6 Loosen Chart knob and rotate chart to position the center of the printhead in the middle of the START CIRCLE 7 Tighten chart knob Press and release the CHANGE
22. gs Thermal Style Recorders Thermal alarm relay settings can only be set or reviewed from the Setup mode Install setup chart part number R18 271 Follow the thermal setup Instructions found in Chapter 3 1 4 Pg 21 Alarm settings are set under Alarm 1 and Alarm 2 setpoint categories The setup procedure must be followed completely to properly store selected alarm values Alarms are programmable for hi or low alarm action as well as latching or non latching Latching alarms require a manual reset which is performed by depressing change chart key 3 Note Alarms will reset when pressing the Change Chart key REGARDLESS of the current alarm condition Thermal alarms can be programmed as follows P1 Hi Process high alarm on above setpoint assigned to Pen1 P1 Low Process low alarm on below setpoint assigned to Pen 1 LP1 Hi Latching high alarm LP1 Low Latching low alarm P1 Hi Low Pen 1 uses both optional relays for alarm Alarm 1 is a high alarm Alarm 2 is a low alarm LP1 Hi Low Pen 1 uses both optional relays for latching alarms Alarm 1 is a high latching alarm Alarm 2 is a low latching alarm 3 2 1 OEM Style Recorders No alarm relay options are available on this style recorder UM DR5000 Rev 1 5 2003 Chapter 4 Calibration Ink Type Only 4 1 Pen Arm Calibration Zero and Span Pen calibration applies to ink type units only and is a two point calibration Since Thermal stylus unit print their
23. he LEFT 1 arrow key to select trend for pen 1 or the RIGHT 2 arrow key to select trend for pen 2 Hold the selected key until green LED goes out Then release the key The green LED will begin to flash The printhead will now move to the current trend line value Using LEFT 1 and RIGHT 2 arrow keys adjust the center scribe mark on printhead to desired recording location Once adjusted wait Green LED will got to on steady Printhead will then resume normal operation The remaining pen can now be selected and adjusted if necessary Using instructions above UM DR5000 Rev 1 5 2003 Chapter 5 Power Line Voltage 110 220VAC 50 60Hz Power Consumption 15 VA maximum Input Thermocouple T C Type J K T R B S RTD PT 100 ohm RTD 385 curve Linear 4 20 mA 0 5 VDC Range Programmable See Table 5 1 Common Mode Rejection gt 120dB at 60 Hz Cold Junction Accuracy 0 2 C 25 C ambient Cold Junction Error 0 2 C 25 C ambient Ambient Error 0 0196 span C from 25 C ambient Isolation Inputs isolated from outputs Recording Chart Size 10 Recording Accuracy 0 596 of span 100 division span Sensor Break Full scale Pen 10 seconds Chart Speed Ink Configurable for 4 8 12 24 48 72 or 168 hours Chart Speed Thermal Configurable for 12 24 48 72 or 168 hours Input Filtering Programmable up to 120 seconds Options Relay DPDT 1 0 Amps 2120 VAC resistive Relay Program Process Band Non latching
24. it breakers rated at the minimum value possible All units should be installed inside a suitably grounded metal enclosure to prevent live parts being accessible from human hands and metal tools X All wiring must conform to appropriate standards of good practice and local codes and regulations Wiring must be suitable for maximum voltage current and temperature rating of the system Take care not to over tighten the terminal screws Unused control terminals should not be used as jumper points as they may be internally connected causing damage to the unit Verify that the ratings of the output devices and the inputs as specified in Chapter 5 are not exceeded Je Electric power in industrial environments contains a certain amount of noise in the form of transient voltage and spikes This electrical noise can enter and adversely affect the operation of microprocessor based controls For this reason we strongly recommend the use of shielded thermocouple extension wire which connects the sensor to the unit This wire is a twisted pair construction with foil wrap and drain wire The drain wire is to be attached to earth ground at the sensor end only UM DR5000 Rev 1 5 2003 2 5 Power Wiring The unit is supplied to operate at 110 220VAC 50 60Hz Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the unit L1 L1 37 zr E E P T2 P T El Z c T3
25. n the recorder is not in service To remove the pen cap gently lift the pen arm away from the chart paper Remove the black plastic pen cap to expose the fiber tip of the ink pen and gently place the pen back onto the chart paper Do not let the pen arm snap back onto the chart paper This will flatten the fiber tip of the pen and will no longer give you a fine line marking on the chart paper Place the pen cap in a safe place for future use If the stylus does not touch the chart adjustment can be made by slightly bending the metal pen arm in the center towards the chart paper Do not use more pressure than is necessary to create a fine line marking on the chart paper Note As the pen ink supply runs out the pen color will become lighter This indicates that the pen should be replaced CHANGE CHART Figure 2 7 Keypad Layout UM DR5000 Rev 1 5 2003 2 12 1 Marking Systems Thermal This type of pen consists of a self contained thermal print head that is attached to a metal Stylus pen arm assembly Periodic maintenance is not reguired for this pen type Since the thermal print head creates it s own chart adjustment for outer ring are made automatically during each chart change Replacement of the thermal print head is covered in 2 13 1 Pg 16 2 13 Replacement of Pen Ink Type Recorders that are eguipped with fiber tipped cartridge pens are colored coded RED for pen 1 and BLUE for pen 2 The pen cartridge is securely fasten
26. nd release CHANGE CHART key 3 14 LED will remain on steady pen will stop at 100 ring then to alarm setpoint values if enabled LED will turn off when pen s reaches alarm setpoint Use RIGHT LEFT arrow keys to adjust alarm value s for pen LED is on steady when pen s are recording actual values CHANGE CHART Figure 3 1 Keypad Layout UM DR5000 Rev 1 5 2003 3 1 2 Setup Of Dual Pen OEM Ink Style In order to configure the recorder you will need the recorder SET UP CHART P N R18 270 CCW or P N R18 272 CW The second pen Blue on OEM type recorders is fixed for 0 100 of the analog input The setup chart contains the configuration categories of the recorder Probe Input Inner Chart Values Outer Chart Values Units Chart Rotation Input Averaging and Relay Options Place the SET UP CHART onto the recorder This setup chart could be left on the recorder behind the normal recording chart for easy access or behind the platen assembly 1 2 10 11 Place SETUP CHART on recorder Press and release CHANGE CHART Rey 3 pens vvill begin move off scale and green LED will flash rapidly VVait until pens are off scale AND Green LED goes to on steady Press and hold LEFT arrow key 1 until green LED turns off Then release key Pens will move to outer ring Wait for green LED to flash slowly 8sec on 8sec off Note Green LED will continue to flash slowly during setup mode Blue Pen will move to outer ring of
27. our own chart technology includes real time trend and digital data directly on the chart The unit is powered by 110 220VAC 50 60Hz Programmable inputs for thermocouple types J K T R B and S as well as 4 20mA or 0 5VDC are standard Optional alarm relays are available and programmable for low high or band operation A green LED indicates unit is recording A unigue setup chart provides the user with an on the spot manual This setup chart will also self document the current setup for guick review by an operator High accuracy maximum flexibility fast response and a simple user interface are the main benefits of the DR 5000 recorder UM DR5000 Rev 1 5 2003 1 2 DR 5000 Ordering Code DR5000 J ll El Ell UU LJ Power Input 1 110 220VAC 50 60HZ Selectable Recording Style 1 1 Pen Ink 2 2 Pen Ink 3 1 Pen Thermal 4 2 Pen Thermal 5 2 Pen OEM Ink Style Outputs 0 None Standard on OEM style no relays 1 1 Relay DPDT 1A 240VAC resistive 2 2 Relay DPDT 1A 240VAC resistive Display Options 0 None Chart Option 1 10 Counterclockwise Rotation 2 10 Clockwise Rotation Counterclockwise ONLY on thermal units Enclosure Options 1 Standard Nema 3 2 Nema 4X 3 Platen Mount Special Options 0 None 1 Battery Backup Suffix Blank Standard FDC Namestrip Suffix AA ZZ Door Namestrip Identifier OEM Unit Pen 1 Universal Input Pen 2 4 20 ma ONLY No rel
28. reen LED will go out Release the key The green LED will begin to flash Adjust the pen to the desired value This is done using the LEFT 1 or RIGHT 2 arrow keys Once the corrected value is obtained wait Green LED will go to on steady indicating normal recording mode CHANGE CHART Figure 4 2 Keypad Layout UM DR5000 Rev 1 5 2003 4 3 Thermal Style Probe Offset Pen Offset This recorder has been accurately calibrated at the factory Before making any adjustments this instrument should be in service for 24 hours Thereafter if any adjustment is reguired perform the following procedure 1 Place a Certified Test Thermometer s alongside the recorder s sensor probe s in a monitored controlled condition Once the temperature has leveled out compare the position of the pen on the recorder to the test thermometer s reading also compare the Certified Test Thermometer s reading to the second pen of the recorder If an adjustment is reguired for a single pen unit depress and hold either the LEFT 1 or RIGHT 2 arrow key The printhead will move to current trend line value Using the LEFT 1 and RIGHT 2 arrow keys adjust the center scribe mark on printhead to desired recording location Once adjusted wait Green LED will go to on steady Printhead will then resume normal printing operation For two 2 pen thermal recorders you must first select the trend line that you wish to calibrate This is done by pressing t
29. s See Figure 2 3 If the length of thermocouple plus the extension wire is too long it may affect the temperature measurement A 400 ohms K type or a 500 ohms J type thermocouple lead resistance will produce approximately 1 degree C temperature error Figure 2 4 Single Pen Ink Style Inputs QO O 8 00000000 Relay T oaa O0000000 15 FO ODOFTJIA TT 3 eo LLI o LL e DC MA ZH e 3 ma 3b TC 4 UM DR5000 Rev 1 5 2003 Figure 2 5 Two Pen OEM Ink Style Inputs Of A e 0 am E use nn m Wiring RED d vDC MA 20 se I t S 2 B e jih z S 3U amp 3 TC zs Sa zam Pen 2 Input z SG Wiring 6 2 C3 4 20 ma ONLY Main Board Fig 2 6 Two Pen Universal and Thermal Inputs 1 RED RTD a MES s E sli F2 voca 26 o tj INDO NONE 4 so I wmm C A 3 4 a Relay Connections Optional xs PEN 2 Relay Tm i i Optional W oo ooo Relay Connections l 998998 are DPDT Relays EH MA Relay Connections PEN 1 UM DR5000 Rev 1 5 2003 Input Wiring Pen 1 Pen 2 PEN 1 9999 co 6096 PEN 2 2 amar IME ni 2 8 RTD Input Wiring RTD connections are shown in the previous with the compensating lead connected to terminal 4 For two wire RTD inputs terminals 2 and 4 should be linked The three wire RTD offers the capability of lead resistance compensation
30. s T3 d z L2 T4 T4 L2 D 110 VAC Wiring D 220 VAC Wiring Earth Ground Earth Ground Connection Connection Figure 2 2 Power Supply The recorder uses AC power when it is operating normally The battery back up option on ink recorders will allow the recorder to operate for approximately 48 hours in case of a power loss AC input can be fused with a 250VAC 5 Amp fuse In order to connect the recorder to the main AC power you must first gain access to the microprocessor PC board that is mounted to the back of the chart plate Your recorder will have a hinged chart plate held in place by two 2 screws located on the right hand side of the chart plate Remove these two screws and open the hinged chart plate If you are not sure how to access the back of the chart plate please contact FUTURE DESIGN CONTROLS before continuing The AC power connections are made to the 4 pin terminal block located on back side of platen All AC and ground wires must be a minimum of 16 AWG Refer to Figure 2 2 for proper connection to the main AC power Earth Ground must be connected at ground lug provided See Figure 2 2 A This eguipment is designed for installation in an enclosure which provides adeguate protection against electric shock Grounding of thisrecorder must meet national and local codes Ground wire should be Color coded GREEN or GREEN with a YELLOW stripe Local reguirements regarding electrical installation should be rigidly observed Considera
31. tion should be given to prevent unauthorized persons access to the power terminals UM DR5000 Rev 1 5 2003 2 6 Sensor Installation Proper sensor installation can eliminate many problems in a control system The probe should be placed so that it can detect any temperature change with minimal thermal lag In a process that reguires fairly constant heat output the probe should be placed close to the heater In a process where the heat demand is variable the probe should be close to the work area Some experiments with probe location are often reguired to find this optimum position Proper sensor type is also a very important factor to obtain precise measurements The sensor must have the correct temperature range to meet the process reguirements In special processes the sensor might need to have different reguirements such as leak proof anti vibration Standard thermocouple sensor limits of error are 4 degrees F 2 degrees C or 0 75 of sensed temperature plus drift caused by improper protection or an over temperature occurrence This error is far greater than controller error and cannot be corrected at the sensor except by proper selection and replacement In order to connect the probe input device to the recorder you must first gain access to the microprocessor PC board that is mounted to the back of the chart plate A ferrite bead has been included to provide additional protection for electrical Noise sensor signal wires can pi
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