XC-130

Printed in U.S.A. August 19, 1999

Manufacturers of Precision Instruments

OPERATION, MAINTENANCE, AND SPARE PARTS LIST

Bulk Tank SystemGalaxy II & III

Part Number XC-130Revision A

Manual XC-130 contains 140 pages as follows:

Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8/19/99ii through iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/19/99TOC-1 through TOC-6 . . . . . . . . . . . . . . . . . . . . .8/19/99LOF-1 through LOF-4 . . . . . . . . . . . . . . . . . . . . . . 8/19/99LOT-1 through LOT-2 . . . . . . . . . . . . . . . . . . . . . . 8/19/991-1 through 1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/19/992-1 through 2-14 . . . . . . . . . . . . . . . . . . . . . . . . . . 8/19/993-1 through 3-30 . . . . . . . . . . . . . . . . . . . . . . . . . . 8/19/994-1 through 4-12 . . . . . . . . . . . . . . . . . . . . . . . . . . 8/19/99A-1 through A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . 8/19/99B-1 through B-6 . . . . . . . . . . . . . . . . . . . . . . . . . . 8/19/99C-1 through C-8 . . . . . . . . . . . . . . . . . . . . . . . . . . 8/19/99D-1 through D-6 . . . . . . . . . . . . . . . . . . . . . . . . . . 8/19/99E-1 through E-4 . . . . . . . . . . . . . . . . . . . . . . . . . . 8/19/99F-1 through F-14. . . . . . . . . . . . . . . . . . . . . . . . . . 8/19/99G-1 through G-12 . . . . . . . . . . . . . . . . . . . . . . . . . 8/19/99H-1 through H-4 . . . . . . . . . . . . . . . . . . . . . . . . . . 8/19/99

All product, brand, or trade names used in this publication are the trademarks or registered trade-marks of their respective owners.

Information in this manual is subject to change without notice.

ii August 19, 1999M/D TOTCO

IMPORTANT SAFETY NOTICE

Proper service and repair is important to the safe, reliable operation of all M/D TOTCO equipment. The service procedures recommended by M/D TOTCO and described in the technical manuals are recommended methods of performing service operations. When these service operations require the use of tools specially designed for the purpose, those special tools should be used as recommended. Warnings against the use of specific service methods that can damage equipment or render it unsafe are stated in the manuals. These warnings are not exclusive, as M/D TOTCO could not possibly know, evaluate and advise service people of all conceivable ways in which ser-vice might be done or of all possible associated hazardous consequences. Accordingly, anyone who uses service procedures or tools which are not recommended by M/D TOTCO must first sat-isfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized by the method selected.

August 19, 1999 iiiM/D TOTCO

LIMITED PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

Martin-Decker TOTCO (“Company”) warrants to Buyer (“Purchaser”) of new products manufactured or supplied by the Company that such products are, at the time of delivery to the Purchaser, free of material and workmanship defects, subject to the following exceptions:

A.Any product which has been repaired or altered in such a way, in the Company's judgement, as to affect the product adversely, including any repairs, rebuilding, welding or heat treating outside of Company authorized facility.

B.Any product which has, in the Company's judgement, been subject to negligence, accident, or improper storage.

C.Any product which has not been installed, operated and maintained in accordance with normal practice and within the recommendations of the Company.

D.For all items of special order by Buyer which are not manufactured by Company, Buyer should submit warranty claims directly to the manufacturer thereof.

The Company's obligation under this warranty is limited to repairing, or at its option, replacing any products which in its judgement proved not to be as warranted within the applicable warranty period. All costs of transportation of products claimed not to be as warranted to authorized Company service facility shall be borne by Buyer. Costs of return transportation to Buyer of products accepted for repair or replacement by Company under the warranty provisions of the Sales Agreement shall be borne by the Company. Company may, at its sole option elect to refund the purchase price of the products, and Company shall have no further obligation under the Sales Agreement.

The cost of labor for installing a repaired or replacement part shall be borne by Buyer. Replacement parts provided under the terms of this warranty are warranted for the remainder of the warranty period of the product upon which installed to the same extent as if such parts were original components thereof.

The warranty periods for various products are:

A.Hydraulic, Mechanical, Electronic Equipment: one (1) year from date of installation or fifteen (15) months from date of shipment from Company, whichever occurs first.

B.All Elastomer Diaphragms: six (6) months from date of shipment from Company.

No deviations from the Company's standard warranty terms or period as stated herein will be honored unless agreed to in writing by an authorized Company representative prior to acceptance of the order.

EXCLUSIVITY OF REMEDY AND LIMITATION OF LIABILITY. THE REMEDIES PROVIDED FOR IN THIS WARRANTY SHALL CONSTITUTE THE SOLE RECOURSE OF BUYER AGAINST COMPANY FOR BREACH OF ANY OF COMPANY'S OBLIGATIONS UNDER THE SALES AGREEMENT WITH BUYER, WHETHER THE CLAIM IS MADE IN TORT OR IN CONTRACT, INCLUDING CLAIMS BASED ON WARRANTY, NEGLIGENCE, OR OTHERWISE.

IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT, STRICT LIABILITY OR IN TORT (INCLUDING NEGLIGENCE), NOR FOR LOST PROFITS.

iv August 19, 1999M/D TOTCO

Table of Contents
CHAPTER 1OVERVIEW
1-1 Introduction......................................................................................................................... 1-11-2 Scope of Manual ................................................................................................................. 1-11-3 Intended Audience .............................................................................................................. 1-11-4 Personnel Qualifications ..................................................................................................... 1-11-5 Notes, Cautions, and Warnings........................................................................................... 1-21-6 System Overview................................................................................................................ 1-31-7 PI2000 Specifications ......................................................................................................... 1-6

1-7-1 Display ....................................................................................................................... 1-61-7-2 Analog Inputs............................................................................................................. 1-61-7-3 Digital Inputs ............................................................................................................. 1-61-7-4 Sensor Excitation ....................................................................................................... 1-61-7-5 Outputs....................................................................................................................... 1-7

1-7-5-1 Analog outputs .................................................................................................. 1-71-7-5-2 Aux Comm (Half-duplex)................................................................................. 1-7

1-7-6 Alarms........................................................................................................................ 1-71-7-6-1 Industry standard plug-in relays ....................................................................... 1-7

1-7-7 Environmental............................................................................................................ 1-71-7-8 Input Power................................................................................................................ 1-71-7-9 Enclosure ................................................................................................................... 1-71-7-10 Certification ............................................................................................................... 1-8

1-7-10-1 Safe area rating ................................................................................................. 1-81-7-10-2 Class 1, Division 2 area .................................................................................... 1-8

1-8 Front Panel for PI 2000....................................................................................................... 1-8

CHAPTER 2NORMAL OPERATION

2-1 PI2000 Power Up................................................................................................................ 2-12-2 The Operator’s Screen ........................................................................................................ 2-22-3 How to Navigate Screens and Menus ................................................................................. 2-2

2-3-1 Keypad Functionality................................................................................................. 2-22-3-2 Label Bars .................................................................................................................. 2-2

2-3-2-1 Operator’s Screen Label Bar............................................................................. 2-32-3-2-2 Menu Label Bar ................................................................................................ 2-32-3-2-3 Item Label Bar .................................................................................................. 2-32-3-2-4 Data-Entry Label Bar........................................................................................ 2-32-3-2-5 ACK Label Bar ................................................................................................. 2-3

2-4 Keypad Labels on the Operator’s Screen............................................................................ 2-42-4-1 ACK (Acknowledge Alarms) Key............................................................................. 2-4

2-4-1-1 Using the ACK key to Silence a Horn.............................................................. 2-42-4-1-2 Using the Ack Key to Clear All Relays ............................................................ 2-5

August 19, 1999 Table of Contents-1M/D TOTCO

Table of Contents Bulk Tank System Manual XC-130

2-4-2 CAL Key.................................................................................................................... 2-52-4-2-1 Verifying Weight-Sensor Calibration............................................................... 2-62-4-2-2 Entering Numbers Into the Scratch Pad............................................................ 2-6

2-4-3 SCREEN Key ........................................................................................................ 2-82-4-4 Using the Screen Menu to Select a Screen Layout .................................................... 2-92-4-5 Screen Menu Layout Options .................................................................................... 2-9

2-4-5-1 Four Digital..................................................................................................... 2-102-4-5-2 Two Bar .......................................................................................................... 2-112-4-5-3 Two Bar, Screen 2 .......................................................................................... 2-12

2-4-6 MENU Key .............................................................................................................. 2-132-5 Bulk Tank Valve Switches ............................................................................................... 2-14

CHAPTER 3CONFIGURATION AND CALIBRATION

3-1 Menus and Screens ............................................................................................................. 3-23-2 Alarm Setpoints Screen ...................................................................................................... 3-3

3-2-1 Entering Alarm Setpoints........................................................................................... 3-33-3 Display Adjust Screen ........................................................................................................ 3-4

3-3-1 Adjusting Display Contrast........................................................................................ 3-43-3-2 Adjusting the Backlight Brightness ........................................................................... 3-53-3-3 Adjusting the Backlight Color ................................................................................... 3-53-3-4 Adjusting the Slow Update ........................................................................................ 3-6

3-4 Graph Scales Screen ........................................................................................................... 3-63-4-1 Entering Graph Scale Values ..................................................................................... 3-7

3-5 Calibration Submenu .......................................................................................................... 3-83-6 Cal Check Screen................................................................................................................ 3-8

3-6-1 Verifying Weight-Sensor Calibration ........................................................................ 3-93-6-2 Entering Numbers Into the Scratch Pad..................................................................... 3-9

3-7 Two-Point Calibration Screen .......................................................................................... 3-103-7-1 Physical Load Calibration for Weight ..................................................................... 3-113-7-2 Shunt Calibration (Remote Calibration) .................................................................. 3-123-7-3 Voltage Substitution Calibration ............................................................................. 3-13

3-8 Data Calibration Screen .................................................................................................... 3-153-9 Analog-Output Calibration Screen ................................................................................... 3-163-10 System Setup Menu .......................................................................................................... 3-20

3-10-1 Operator Privileges Screen ...................................................................................... 3-203-10-2 Units of Measure Screen.......................................................................................... 3-213-10-3 Relay Setup Submenu.............................................................................................. 3-23

3-10-3-1 Alarm Assignments Submenu ........................................................................ 3-243-10-3-2 Relay Type Submenu...................................................................................... 3-25

3-10-4 Network Setup Screen ............................................................................................. 3-263-10-4-1 Configuring the Instrument as a Sensor Input Unit ........................................ 3-263-10-4-2 Configuring the Instrument as a Remote Display Unit................................... 3-27

3-10-5 Aux. Comm. Setup Screen....................................................................................... 3-28

Table of Contents-2 August 19, 1999M/D TOTCO

Bulk Tank System Table of ContentsManual XC-130

CHAPTER 4TROUBLESHOOTING, DIAGNOSTICS, and

MAINTENANCE4-1 Overview............................................................................................................................. 4-14-2 Navigating the Menus ......................................................................................................... 4-14-3 Diagnostic Menus ............................................................................................................... 4-2

4-3-1 Raw Counts (troubleshooting diagnostic).................................................................. 4-24-3-2 Power Supplies (run time background) ..................................................................... 4-24-3-3 Error Logs (troubleshooting diagnostic).................................................................... 4-3

4-3-3-1 Local (or Sensor) Network Errors .................................................................... 4-44-3-3-2 Local (or Sensor) Hardware Errors................................................................... 4-5

4-3-4 Self Tests.................................................................................................................... 4-64-3-4-1 Self Test Results ............................................................................................... 4-64-3-4-2 Perform Self Tests ............................................................................................ 4-74-3-4-3 Load Factory Defaults ...................................................................................... 4-7

4-3-5 Relays-Alarms Disabled ............................................................................................ 4-84-3-6 Options (troubleshooting diagnostic)......................................................................... 4-84-3-7 SPI Diagnostics (run-time background) .................................................................... 4-9

4-4 Software Update Procedure ................................................................................................ 4-94-5 Error Symbols ................................................................................................................... 4-114-6 Periodic Maintenance ....................................................................................................... 4-11

Appendix AGLOSSARY

A-1 Special Terms, Acronyms, and Abbreviations .................................................................. A-1

Appendix BALARMS AND RELAYS

B-1 Overview.............................................................................................................................B-1B-2 Relay Contact Types ...........................................................................................................B-1

B-2-1 Normally Open Contacts vs. Normally Closed Contacts ..........................................B-1B-2-2 Mechanical Contacts vs. Solid State Contacts...........................................................B-2

B-3 Horn vs. Relay ....................................................................................................................B-2B-3-1 Fail-safe vs. De-energized .........................................................................................B-3B-3-2 Horn Relay vs. General-Purpose Relay .....................................................................B-3B-3-3 Latched vs. Unlatched................................................................................................B-3B-3-4 Cal Relays ..................................................................................................................B-3

B-4 Alarm Operation .................................................................................................................B-4B-5 Alarm and Relay Programming via the Front Panel...........................................................B-4

B-5-1 Alarm Assignments....................................................................................................B-4B-5-2 Relay Types ...............................................................................................................B-5

B-6 Tips and Hints .....................................................................................................................B-5



Appendix CSTRAIN GAUGE SENSOR CALIBRATION TECHNIQUES

C-1 Overview.............................................................................................................................C-1C-2 Physical Calibration ............................................................................................................C-1

C-2-1 Physical Calibration Procedure..................................................................................C-1C-3 Shunt Calibration (Shuntcal) ..............................................................................................C-2

C-3-1 Shuntcal Procedure ....................................................................................................C-3C-4 Voltage Substitution ...........................................................................................................C-4

C-4-1 Voltage Substitution Procedure .................................................................................C-4C-5 Bridge Substitution .............................................................................................................C-6C-6 Application Notes ...............................................................................................................C-6

C-6-1 Routine Calibration....................................................................................................C-7C-7 Product Features .................................................................................................................C-7

Appendix DSTRAIN GAUGE LOAD CELL TROUBLESHOOTING

D-1 Overview............................................................................................................................ D-1D-2 Excitation Voltage Requirements ...................................................................................... D-1D-3 Load Cell Signal ................................................................................................................ D-2D-4 Bridge Resistance .............................................................................................................. D-3D-5 Insulation Resistance ......................................................................................................... D-3D-6 Interconnect Techniques .................................................................................................... D-3D-7 Troubleshooting Techniques.............................................................................................. D-4

D-7-1 Insulation Resistance ................................................................................................ D-4D-7-2 Cable Insulation Resistance ...................................................................................... D-5D-7-3 Bridge Resistance ..................................................................................................... D-5D-7-4 Excitation Voltage .................................................................................................... D-5D-7-5 Signal Voltage........................................................................................................... D-5

Appendix EOPTION MODULES

E-1 Overview.............................................................................................................................E-1E-2 Analog Output Module .......................................................................................................E-1E-3 Aux Comm Module ............................................................................................................E-2E-4 Event Input Module ............................................................................................................E-2E-5 Installation ..........................................................................................................................E-3

Appendix FAUXILIARY COMMUNICATIONS (AUX COMM)

F-1 Overview............................................................................................................................. F-1F-2 Protocol Selection ............................................................................................................... F-1F-3 Command List..................................................................................................................... F-1F-4 Delimiter Selection ............................................................................................................. F-2


Bulk Tank System Table of ContentsManual XC-130

F-5 PROTOCOL #1 .................................................................................................................. F-3F-5-1 SS Command ............................................................................................................. F-5F-5-2 CS Command............................................................................................................. F-5F-5-3 CD Command ............................................................................................................ F-6

F-6 Protocol #2 .......................................................................................................................... F-7F-6-1 CD Command ............................................................................................................ F-8F-6-2 SS Command ............................................................................................................. F-9F-6-3 CS Command........................................................................................................... F-10F-6-4 AK Command .......................................................................................................... F-10F-6-5 C1 Command ........................................................................................................... F-10F-6-6 C2 Command ........................................................................................................... F-10F-6-7 RS Command........................................................................................................... F-10F-6-8 ST Command ........................................................................................................... F-10F-6-9 RT Command........................................................................................................... F-11

F-7 Aux Comm Response Times ............................................................................................ F-13F-7-1 SS (single scan) Command ...................................................................................... F-13F-7-2 C1 (CAL1) Command ............................................................................................. F-13F-7-3 CD (Configuration Dump) command: .....................................................................F-13F-7-4 Conclusions on Response Time............................................................................... F-13

Appendix GNETWORKING

G-1 Overview............................................................................................................................ G-1G-2 Sensor Input Unit ............................................................................................................... G-1

G-2-1 Sensor Input Unit With Display................................................................................ G-1G-2-2 Sensor Input Unit Without Display (DAQ) .............................................................. G-1

G-3 Remote Display.................................................................................................................. G-1G-4 Sensor Input Unit Setup ..................................................................................................... G-2G-5 Remote Display Unit Setup ............................................................................................... G-2G-6 Network Examples............................................................................................................. G-3

G-6-1 Network #1—Remote DAQ to Remote Display ...................................................... G-3G-6-2 Network #2—Sensor/Display to Remote Display .................................................... G-4G-6-3 Network #3—DAQ to Multiple Remote Displays ................................................... G-4G-6-4 Network #4—Sensor/Display to Multiple Remote Displays.................................... G-5G-6-5 Network #5—Remote Display to Multiple DAQs ................................................... G-6G-6-6 Network #6—Remote Display to Multiple Sensor/Displays.................................... G-7G-6-7 Network #7—Multiple Remote DAQs to Multiple Remote Displays...................... G-8G-6-8 Network #8—Multiple Sensor/Display Units to Multiple Remote Displays ........... G-9

G-7 Networking and Aux Comm............................................................................................ G-10G-8 Network/Aux Comm Examples....................................................................................... G-10

G-8-1 Network #9—Multi. Sensor/Display to Multi. Remote Displays w/ Aux Comm.. G-11G-8-2 Network #10—Multi. Sensor/Display w/ Aux Comm to Multi. Remote Displays G-12



Appendix HINTERCONNECT EXAMPLE DRAWINGS

H-1 Overview...............................................................................................................................13

Appendix IILLUSTRATED PARTS LISTS

I-1 Overview.............................................................................................................................. I-1


List of Figures
CHAPTER 1OVERVIEW
Figure 1-1. Bulk Tank System Main Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Figure 1-2. Bulk Tank System Remote Cement Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Figure 1-3. Bulk Tank System Remote Mud Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Figure 1-4. Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9


Figure 2-1. Operator’s Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Figure 2-2. Operator’s Screen Label Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Figure 2-3. Menu Label Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Figure 2-4. Item Label Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Figure 2-5. Data-Entry Label Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Figure 2-6. ACK Label Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Figure 2-7. Acknowledge Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Figure 2-8. Cal Check Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Figure 2-9. Data-Entry Label Bar on the Cal Check Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Figure 2-10. Screen Menu for a Sensor Display Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8Figure 2-11. Screen Menu for a Remote Display Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8Figure 2-12. Four Digital Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10Figure 2-13. Two Bar Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11Figure 2-14. 2 Bar, Screen 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12Figure 2-15. Main Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13Figure 2-16. Main Console Mimic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14Figure 2-17. Valve Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15


Figure 3-1. Navigation Routes From the Operator’s Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Figure 3-2. Main Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Figure 3-3. Alarm Setpoints Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Figure 3-4. Data-Entry Label Bar on the Alarm Setpoints Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Figure 3-5. Display Adjust Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Figure 3-6. Data-Entry Label Bar on the Display Adjust Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Figure 3-7. Data-Entry Label Bar on the Display Adjust Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Figure 3-8. Graph Scales Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Figure 3-9. Data-Entry Label Bar on the Graph Scales Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Figure 3-10. Calibration Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Figure 3-11. Cal Check Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Figure 3-12. Data-Entry Label Bar on the Cal Check Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Figure 3-13. Two-Point Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Figure 3-14. Data-entry Label Bar on the Two-Point Calibration Screen. . . . . . . . . . . . . . . . . . . . . . . 3-11Figure 3-15. Data-entry Label Bar on the Two-Point Calibration Screen. . . . . . . . . . . . . . . . . . . . . . . 3-12Figure 3-16. Data-entry Label Bar on the Two-Point Calibration Screen. . . . . . . . . . . . . . . . . . . . . . . 3-13Figure 3-17. Data Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Figure 3-18. Data-entry Label Bar on the Data Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Figure 3-19. Data-entry Label Bar on the Data Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16Figure 3-20. Analog Output Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

August 19, 1999 List of Figures-1M/D TOTCO

List of Figures Bulk Tank System Manual XC-130

Figure 3-21. Data-entry Label Bar on the Analog Output Cal Screen . . . . . . . . . . . . . . . . . . . . . . . . . 3-18Figure 3-22. System Setup Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20Figure 3-23. Operator Privileges Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21Figure 3-24. Units of Measure Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22Figure 3-25. Data-entry Label Bar on the Units of Measure Submenu . . . . . . . . . . . . . . . . . . . . . . . . 3-22Figure 3-26. Relay Setup Submenu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23Figure 3-27. Alarm Assignments Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24Figure 3-28. Relay Type Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25Figure 3-29. Network Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27Figure 3-30. Aux. Comm. Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28Figure 3-31. Data-entry Label Bar on the Aux. Comm. Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . 3-28


MAINTENANCEFigure 4-1. Navigation Route from Operator’s Screen to Diagnostics Menu . . . . . . . . . . . . . . . . . . . . 4-1Figure 4-2. Raw Counts Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Figure 4-3. Error Log Menu for a Remote Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Figure 4-4. Error Log Menu for a Sensor Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Figure 4-5. Local Network Error Log Screen for a Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Figure 4-6. Hardware Error Log for a Sensor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Figure 4-7. Self Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Figure 4-8. Self Test Results Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Figure 4-9. Relays-Alarms Disabled Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Figure 4-10. Options Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Figure 4-11. SPI Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

APPENDIX CSTRAIN GAUGE SENSOR CALIBRATION TECHNIQUES

Figure C-1. Shunt Calibration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2Figure C-2. Resistor Divider for Voltage Substitution Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4Figure C-3. Resistor Divider for Bridge Substitution Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

APPENDIX DSTRAIN GAUGE LOAD CELL TROUBLESHOOTING

Figure D-1. Signal Detection Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2Figure D-2. 4-Wire Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3Figure D-3. 6- or 7-Wire Configuration Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4

APPENDIX EOPTION MODULES

Figure E-1. Series 2000 Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1Figure E-2. Series 2000 Back Cover (Option Module Socket Covers Highlighted) . . . . . . . . . . . . . . . E-3Figure E-3. How to Properly Seat an Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4

APPENDIX GNETWORKING

List of Figures-2 August 19, 1999M/D TOTCO

Bulk Tank System List of FiguresManual XC-130

Figure G-1. Rotary Address Switch Location on Rear Panel of Instrument . . . . . . . . . . . . . . . . . . . . . G-2Figure G-2. Remote DAQ to Remote Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3Figure G-3. Sensor/Display to Remote Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4Figure G-4. DAQ to Multiple Remote Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4Figure G-5. Sensor/Display to Multiple Remote Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5Figure G-6. Remote Display to Multiple DAQs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6Figure G-7. Remote Display to Multiple Sensor/Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7Figure G-8. Multiple Remote DAQs to Multiple Remote Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8Figure G-9. Multiple Sensor/Display Units to Multiple Remote Displays . . . . . . . . . . . . . . . . . . . . . . . G-9Figure G-10. Multiple Sensor/Display to Multiple Remote Displays w/ Aux Comm . . . . . . . . . . . . . . . G-11Figure G-11. Multiple Sensor/Displays w/ Aux Comm to Multiple Remote Displays . . . . . . . . . . . . . . G-12

August 19, 1999 List of Figures-3M/D TOTCO

List of Figures Bulk Tank System Manual XC-130

List of Figures-4 August 19, 1999M/D TOTCO

August 19, 1999 List of Tables-1M/D TOTCO

List of TablesCHAPTER 2

NORMAL OPERATION

Table 2-1. Operator’s Screen Keypad Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Table 2-2. Keypad Functionality in Menu Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2


Table 3-1. Non-Isolated Analog Voltage Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 Table 3-2. Non-Isolated Analog Current (Sourced) Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 Table 3-3. Isolated Analog Current (2-wire transmitter) Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17


MAINTENANCE

Table 4-1. Error Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

APPENDIX CSTRAIN GAUGE SENSOR CALIBRATION TECHNIQUES

Table C-1. Shuntcal Value Approximations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

APPENDIX IILLUSTRATED PARTS LISTS

Table I-1. Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

CHAPTER 1OVERVIEW

1-1 IntroductionThis manual contains operation, maintenance and parts information for the Galaxy II Bulk Tank System. Information in this manual should enable qualified personnel to install, operate and trou-bleshoot these systems.

1-2 Scope of ManualThis manual is divided into the following chapters:

CHAPTER 1—OVERVIEWCHAPTER 2—NORMAL OPERATIONCHAPTER 3—CONFIGURATION AND CALIBRATIONCHAPTER 4—TROUBLESHOOTING, DIAGNOSTICS, and MAINTENANCEAPPENDIX A—GLOSSARYAPPENDIX B—ALARMS AND RELAYSAPPENDIX C—STRAIN GAUGE SENSOR CALIBRATION TECHNIQUESAPPENDIX D—STRAIN GAUGE LOAD CELL TROUBLESHOOTINGAPPENDIX E—OPTION MODULESAPPENDIX F—AUXILIARY COMMUNICATIONS (AUX COMM)APPENDIX G—NETWORKINGAPPENDIX H—INTERCONNECT EXAMPLE DRAWINGSAPPENDIX I—ILLUSTRATED PARTS LISTS

1-3 Intended AudienceThis manual is intended for use by field engineering, installation, operation and repair personnel.

1-4 Personnel QualificationsThe procedures described in this manual should be performed only by persons who have read the safety notice on page iii of this manual and who are fully qualified and trained to perform the pro-cedures in this manual.

August 19, 1999 Page 1-1M/D TOTCO

CHAPTER 1 Bulk Tank SystemNotes, Cautions, and Warnings Manual XC-130

1-5 Notes, Cautions, and WarningsNotes, cautions and warnings are presented, when applicable, to aid in understanding and operat-ing the equipment or to protect personnel and equipment. Examples and explanations follow.

NOTEProvides additional information about the current topic.

CAUTIONProvides information to prevent equipment malfunction or damage thatcould result in interruption of service.

WARNING

Provides information to prevent equipment malfunction or damage thatcould result in serious or fatal injury to personnel or major property loss.

Page 1-2 August 19, 1999M/D TOTCO

Bulk Tank System CHAPTER 1Manual XC-130 System Overview

1-6 System OverviewThe Bulk Tank System is a series of consoles and sensors that allow the user to monitor and con-trol the flow of bulk ingredients. Figure 1-1 is an example of the main console.

Figure 1-1. Bulk Tank System Main Panel

PI2000 Monitors

Valve Control Switches

Mimic Panel

for Cement Tanks 1 & 2

PI2000 Monitorsfor Cement Tanks 3 & 4

PI2000 Monitorsfor Mud Tanks 1 & 2

PI2000 Monitorsfor Mud Tanks 3 & 4


CHAPTER 1 Bulk Tank SystemSystem Overview Manual XC-130

Figure 1-2 is an example of the remote cement console.

Figure 1-2. Bulk Tank System Remote Cement Panel

S/C

F1 F3

+

F2

-

F4 F5

M/D TOTCO!

S/C

F1 F3

+

F2

-

F4 F5

M/D TOTCO!

CEMENT

AIR DIS

TANK3

CEMENT

2TANK

AIR DIS

CEMENTTANK

AIR DIS

4

CEMENT

AIR DIS

TANK1

AIR DIS

TANK2

MUD

CEMENT DISCHARGE LINE

MUD FILL/DISCHARGE LINE

MUD DISCHARGE LINE

CEMENT FILL/DISCHARGE LINE

VALVE OPEN

VALVE CLOSED

CEMENT FILL LINE

VENT LINE

MUD FILL LINE

LEGEND


Mimic Panel

PI 2000 Monitors forCement Tanks 1 $ 2

PI 2000Monitorsr forCement Tanks 3 & 4


Bulk Tank System CHAPTER 1Manual XC-130 System Overview

Figure 1-2 is an example of the remote mud console.

Figure 1-3. Bulk Tank System Remote Mud Panel

On the PI2000 monitors, values for pressure and weight are shown digitally by default. The user can choose from other screen arrangements that include bar graphs as well as digital information. When bar graphs are used, alarm values are shown as well. More information about alarms is in CHAPTER 2—NORMAL OPERATION.

The sections that follow describe the PI2000’s features and functions.


Mimic Panel

PI 2000 Monitors forMud Tanks 1 $ 2

PI 2000Monitorsr forMud Tanks 3 & 4


CHAPTER 1 Bulk Tank SystemPI2000 Specifications Manual XC-130

1-7 PI2000 Specifications

1-7-1 Display

• Graphic LCD (240 x 128 pixel)• Viewing area of 114mm wide x 64mm high• Adjustable backlight color (red/green) via front panel• Adjustable backlight brightness via front panel• Adjustable LCD contrast via front panel• Field scalable (full floating point) -999999 to 9999999 (max 7 characters)

including “-” and “.”• Engineering units selectable from predefined list• Display resolution 1, 10, 100, 1000, 0.1, 0.01, 0.001, and 0.0001• Tri-color alarm status LED (green, amber, red)

1-7-2 Analog Inputs

• One each 4–20 mA input; (2 for dual-axis option)• 100 Ω input impedance (0.4 –2.0 V loop drop)• Common mode range: ±200 V operational; 0–24 V specified accuracy• Accuracy: 0.01% FS typical (1 part in 10,000) at 25° C• Temperature drift: 10ppm/C typical (50ppm/C max)• Common mode error: 0.016%/V (virtually eliminated if calibrated in

place)• A/D Conversion:

Technique—16 bit Σ−∆ (0–2.5V = 0–65535 counts)Resolution— >40,000 counts for 4–20 mAInput update rate—16 HzOutput update rate—4 Hz

1-7-3 Digital Inputs

• One quadrature position/speed input activated by:-switch closure pulling to ground (< 3 V)-external voltage applied (12–24 V)-NAMUR type proximity sensor

• Bandwidth 10 kHz

1-7-4 Sensor Excitation

• 24 V available for each analog input and each analog output (max 170 mA total for all 8 I/O combined)

• Position sensor power supply of 5–24 V at 100 mA


Bulk Tank System CHAPTER 1Manual XC-130 PI2000 Specifications

1-7-5 Outputs

1-7-5-1 Analog outputs

• up to three analog output sockets available• individually selectable module types for each parameter• three types of modules:

Non-isolated 4–20 mA sourced (1 kΩ max load)Non-isolated ±10 VDC (5 mA max)Ground isolated 2-wire 4–20 mA transmitter (8–28 V), the volt-age between the + and - signal of this module must remain between 8 and 28 VDC at all times for proper operation

1-7-5-2 Aux Comm (Half-duplex)

• RS232• RS485

1-7-6 Alarms

• Four alarm setpoints (2 high, 2 low) for each displayed parameter

1-7-6-1 Industry standard plug-in relays

• various contact configurations and ratings available• solid state or dry contacts• latching or non-latching (front panel programmable)• fail-safe or de-energized operation

1-7-7 Environmental

• Operating: -20 to +55° C (slow display below -10° C)• Storage: -30 to 80° C

1-7-8 Input Power

• 12–24 VDC (10 W typical, 20 W max)

1-7-9 Enclosure

• Panel mount, NEMA 4X• Optional NEMA 4X dashmount• Optional NEMA 6 panel or dashmount


CHAPTER 1 Bulk Tank SystemFront Panel for PI 2000 Manual XC-130

1-7-10 Certification

1-7-10-1 Safe area rating

• Surge tank display• Main displays• Remote mud displays

1-7-10-2 Class 1, Division 2 area

• Remote cement display

1-8 Front Panel for PI 2000The front panel (Figure 1-4) has five parts:

• A power-on light in the upper left cornerThe power-on light is green when the instrument is powered on and working normally. It also lights up to indicate CPU self-test.

• An alarm light just to the right of the power-on lightThe alarm light is green when there are no alarm conditions, amber when there is at least one low or high alarm condition, and red when there is at least one low-low or high-high alarm condition. It also lights up to indicate CPU self-test.

The alarm light can display three levels of alarm:

Green No alarm conditions

Amber High or Low alarm condition

Red High-High or Low-Low alarm condition

• A Liquid-Crystal Display (LCD) in the center of the unitThe LCD shows screens of constantly updated information about pressure and weight in the form of digital readouts and/or bar graphs. It also serves as the user interface when calibrating or configuring the system.

• A five-position keypad just below the LCDUse this keypad to silence alarms, alarm setpoints, and calibration information.

• A keypad label bar just above the five-position keypadJust above each key on the keypad is a label bar displayed on the LCD that indicates the pur-pose of each key. This label bar will change to match the needs of the user. For example, the Operator’s Screen uses a different label bar from the Cal Check Screen.


Bulk Tank System CHAPTER 1Manual XC-130 Front Panel for PI 2000

Figure 1-4. Front Panel

The operator can read the LCD in sunlight; it is backlit for use at night. Moreover, the brightness and color of the backlight can be adjusted. Color ranges from green to red in small steps (see Chapter 4, Configuration and Calibration).

The display operates in temperature ranges from -20o C to +70o C (-4o F to +158o F).Contrast can be adjusted via the front panel controls. The unit must be stored within the temperature range from -30o C to +80o C (-22o F to +176o F).

Power-On Light Alarm Light


CHAPTER 1 Bulk Tank SystemFront Panel for PI 2000 Manual XC-130



2-1 PI2000 Power UpWhen the unit is powered on, it performs a short self-test and then shows the Operator’s Screen. If the unit is working properly, the power-on light in Figure 2-1 turns green and there is a short, audi-ble beep. The alarm light in Figure 2-1 turns green if there are no values in alarm; it turns amber or red if there are one or more values in an alarm condition.

Figure 2-1. Operator’s Screen

Power-On Light Alarm Light


CHAPTER 2 Bulk Tank SystemThe Operator’s Screen Manual XC-130

2-2 The Operator’s ScreenThe functions of the keys on the Operator’s Screen are shown in Table 2-1:

2-3 How to Navigate Screens and MenusThe unit displays the Operator’s Screen (Figure 2-1) most of the time. However, the operator can choose one of several Operator’s Screens, depending on personal preference and which value is most critical. Refer to Section 2-4-3 later in this chapter for more information about selecting Operator Screen layouts.

The unit has a five button keypad below the LCD that allows the operator to navigate through the unit’s various screens and menus, and to enter configuration values. Just above these five buttons are display labels that show the purpose of each key.

2-3-1 Keypad Functionality

During setup and calibration, the keys have the functions shown in Table 2-2. The excep-tion to this rule is the Operator’s Screen (Figure 2-1) and the MORE key on the Menu Label Bar (Figure 2-3).:

2-3-2 Label Bars

The label bar is dynamic, meaning it changes to indicate the purpose of each key when the operator navigates among the various screens and menus. There are five different label bars used in the screens and menus:

Table 2-1. Operator’s Screen Keypad Function

Key Function

ACK Acknowledge and silence alarms

CAL Verify load calibration

Screen Change the layout of the Operator’s Screen

Main Menu Exit Operator’s screen and display Main Menu

Table 2-2. Keypad Functionality in Menu Screens

Key Label Function

S/C Stop/Cancel, Exit, Abort, Escape

Move Cursor

+ or - Change Value/Selection at cursor location

Enter/Select/Take Action


Bulk Tank System CHAPTER 2Manual XC-130 How to Navigate Screens and Menus

2-3-2-1 Operator’s Screen Label Bar

Figure 2-2 shows the Operator’s Screen label bar.

Figure 2-2. Operator’s Screen Label Bar

2-3-2-2 Menu Label Bar

The Menu Label Bar (Figure 2-3) is displayed when the operator navigates to any menu.

Figure 2-3. Menu Label Bar

2-3-2-3 Item Label Bar

The Item Label Bar (Figure 2-4) is displayed when the operator selects a menu item.

Figure 2-4. Item Label Bar

2-3-2-4 Data-Entry Label Bar

The Data-Entry Label Bar (Figure 2-5) is displayed when the operator wishes to modify a numeric value.

Figure 2-5. Data-Entry Label Bar

2-3-2-5 ACK Label Bar

The ACK Label Bar (Figure 2-6) is displayed when the operator navigates to the Acknowledge screen.

Figure 2-6. ACK Label Bar

DECACK MENUCAL SCREEN

DECEXIT SELECTNEXT MORE

Use then press MODIFYDECEXIT MODIFYNEXT s

ss

Press ENTER when complete

INC DECCANCEL DIGIT> ENTER

ENTER = Clear all relays

EXIT ENTER


CHAPTER 2 Bulk Tank SystemKeypad Labels on the Operator’s Screen Manual XC-130

2-4 Keypad Labels on the Operator’s Screen The following sections provide more information about the Operator Screen keypad functions and how to use them.

2-4-1 ACK (Acknowledge Alarms) Key

The ACK key allows the operator to silence an alarm horn and to clear all relays.

2-4-1-1 Using the ACK key to Silence a Horn

Silence a horn as follows:

1. Press the ACK key on the Operator’s Screen.The ACK key automatically acknowledges and silences the unit’s internal beeper and option relays that control external horns. The Acknowledge Screen appears (Figure 2-7).

Figure 2-7. Acknowledge Screen

2. If the operator wishes only to silence a horn, press EXIT.The Operator’s Screen (Figure 2-1) reappears.


Bulk Tank System CHAPTER 2Manual XC-130 Keypad Labels on the Operator’s Screen

2-4-1-2 Using the Ack Key to Clear All Relays

Clear all optional relays as follows:

1. Press the ACK key on the Operator’s Screen.The ACK key automatically acknowledges and silences the unit’s internal beeper and option relays that control external horns. The Acknowledge Screen (Figure 2-7) appears.

2. Press ENTER.This clears all option relays. The Operator’s Screen (Figure 2-1) reap-pears.

2-4-2 CAL Key

Use the Cal Check Screen to engage remote calibration circuits through optional relays in order to verify weight sensor calibration. Refer to CHAPTER 3—CONFIGURATION AND CALIBRATION for more information.

Figure 2-8. Cal Check Screen

From SensorPresent Reading



2-4-2-1 Verifying Weight-Sensor Calibration

Use the Cal Check Screen to energize remote shunt calibration circuits through optional relays as follows:

1. Press the CAL key on the Operator’s Screen.The Cal Check Screen (Figure 2-8) appears with the CAL 1 status field highlighted in reverse video.

2. Press t or s to select ON or OFF.Select ON to energize remote shunt cal circuits and OFF to deenergize remote shunt cal circuits. Verify that the WEIGHT 1 value displays correct reading.

3. If the operator wishes to change the setting for Cal 2, press NEXT to select CAL 2.The selected data-entry field to the right of CAL 1 or CAL 2 highlights in reverse video to indicate it is active.

4. Press t or s to select ON or OFF.Select ON to energize remote shunt cal circuits and to OFF to deenergize remote shunt cal circuits. Verify WEIGHT 1 value displays correct read-ing.

5. Repeat steps above as necessary for WEIGHT 2.

2-4-2-2 Entering Numbers Into the Scratch Pad

Use the TARGET 1, TARGET 2 and SERIAL NO. fields in the Cal Check Screen to store weight calibration constants entered into the unit from Calibra-tion Data Sheets or by CAL circuit demonstration. These values are visual refer-ences to compare with the CAL circuit WEIGHT 1 value.

Use the Cal Check Screen to verify weight-sensor calibration as follows:

1. Press the CAL key on the Operator’s Screen.The Cal Check Screen (Figure 2-8) appears with the CAL 1 character field highlighted in reverse video.

2. Use the NEXT key to highlight the desired character field to the right of TARGET 1 or TARGET 2. or SERIAL NO.The character field that the operator selects highlights in reverse video to indicate it is active.

3. Press MODIFY.

NOTEThe TARGET1, TARGET2 and SERIAL NUMBER fields are for userconvenience only. The instrument has no “intelligence” regarding thesenumbers.



The Cal Check Screen goes into Configuration Mode, brings up the Con-figuration Label Bar (Figure 2-9), and displays the digit cursor.

Figure 2-9. Data-Entry Label Bar on the Cal Check Screen

4. Use the DIGIT> key to move the cursor to the digit space (one of seven) to be modified.The digit that the operator selects highlights in reverse video.

5. Use the INC and DEC keys to increase or decrease the highlighted digit.

6. Repeat Steps 4 and 5 as needed.

7. Press ENTER to store the value or CANCEL to abort the selection. Pressing either ENTER or CANCEL causes the Cal Check Screen to redis-play the Item Label Bar as shown in Figure 2-8.

8. Use NEXT to highlight another TARGET field or press EXIT to redisplay the Operator’s Screen.





2-4-3 SCREEN Key

Figure 2-10. Screen Menu for a Sensor Display Unit

Figure 2-11. Screen Menu for a Remote Display Unit



2-4-4 Using the Screen Menu to Select a Screen Layout

Select one of these layout options as follows:

1. Press the SCREEN key on the Operator’s Screen.

The Screen Menu (Figure 2-10 or Figure 2-11) appears with the field to the right of LAYOUT highlighted in reverse video to indicate it is active.

2. Scroll through the list of screen layout options in the LAYOUT field by press-ing t or s.The names of the screen layout options appear in reverse video next to the LAYOUT label.

3. When the desired screen layout option appears inside the highlighted field, press MODIFY.The selected Operator’s Screen screen layout appears on the unit’s LCD.

2-4-5 Screen Menu Layout Options

The Screen Menu allows the operator to choose from the following Operator’s Screen lay-out options:

• 4 Digital• 2 Bar• 2 Bar, Screen 2

The three layout options available from the Screen Menu are described in the sections that follow. A procedure for using this menu comes after the layout option descriptions.



2-4-5-1 Four Digital

The Four Digital layout (Figure 2-12) is the default Operator’s Screen. It shows the values for weight and pressure for two tanks using numbers.

Figure 2-12. Four Digital Screen



2-4-5-2 Two Bar

The Two Bar screen shows the pressure and weight of one tank (Tank 1 or 3) with bar graphs and digital readouts. Please note that this screen only shows the data for one tank at a time, to see the other tank’s data (Tank 2 or 4), you must choose the other two bar screen described in Section 2-4-5-3.

Figure 2-13. Two Bar Screen



2-4-5-3 Two Bar, Screen 2

The Two Bar, Screen 2 user screen shows the pressure and weight of one tank (Tank 2 or 4) with bar graphs and digital readouts. Please note that this screen only shows the data for one tank at a time, to see the other tank’s data (Tank 1 or 3), you must choose the other two bar screen described in Section 2-4-5-2.

Figure 2-14. 2 Bar, Screen 2

H



2-4-6 MENU Key

Press the MENU key to bring up the Main Menu in Figure 2-15. This menu is the gateway to all configuration and calibration. For a description of the Main Menu, seeCHAPTER 3—CONFIGURATION AND CALIBRATION.

Figure 2-15. Main Menu


CHAPTER 2 Bulk Tank SystemBulk Tank Valve Switches Manual XC-130

2-5 Bulk Tank Valve SwitchesAt the bottom of the Main, Remote Mud, and Remote Cement panels are several rows of switches (see Figure 1-1 in CHAPTER 1—OVERVIEW). Each of these switches controls one of the valves in the bulk tank system, as mapped on the Mimic Panel (see Figure 2-16)..

Figure 2-16. Main Console Mimic Panel

To activate pumping from a bulk tank, turn the valve control switch to the OPEN position. The valve in question will start to open and continue to open slowly as long as the switch is held in the OPEN position. This allows the user to control the amount of valve opening.


Bulk Tank System CHAPTER 2Manual XC-130 Bulk Tank Valve Switches

If the switch is held to the OPEN position long enough to fully open the valve, the green LED on the mimic panel for that valve illuminates (Figure 2-17 A). When the switch is released, it will return to the center and the valve will maintain its position.

To close the valve, turn the switch to the CLOSE position and hold it there until the red LED on the mimic panel illuminates, signifying that the valve is completely closed (Figure 2-17 B). When the switch is released it will return to the center and the valve will maintain its position.

Figure 2-17. Valve Switch Operation

A

B

Switch Panel

Switch Panel

Mimic Panel

Mimic Panel


CHAPTER 2 Bulk Tank SystemBulk Tank Valve Switches Manual XC-130



This chapter shows how to navigate through and use the Configuration and Calibration menus and screens for changing system values and presets. The operator begins from the Operator’s Screen. For a complete description of the Operator’s Screen, refer to CHAPTER 2—NORMAL OPERATION.

Figure 3-1 is a menu tree that shows the navigation routes from the Operator’s Screen. The Configuration and Calibration menus and screens are available from the Main Menu.

Figure 3-1. Navigation Routes From the Operator’s Screen

AlarmSetpoints

Network Setup

Aux Comm Setup


CHAPTER 3 Bulk Tank SystemMenus and Screens Manual XC-130

3-1 Menus and ScreensThe Main Menu is shown in Figure 3-2. The following is a list of Main Menu labels and their func-tions:

EXIT Exits the Main Menu and returns to the Operator’s Screen

NEXT Moves the highlight to the next item in the list of menu choices.

MORE Displays a continuation of menu items.

SELECT Selects the highlighted menu item and displays a submenu or screen.

Figure 3-2. Main Menu

To select an item in the Main Menu, use the NEXT key to highlight the desired item; then press the SELECT key.


Bulk Tank System CHAPTER 3Manual XC-130 Alarm Setpoints Screen

3-2 Alarm Setpoints ScreenUse the Alarm Setpoints Screen to enter setpoint values for weight and pressure.

Figure 3-3. Alarm Setpoints Screen

3-2-1 Entering Alarm Setpoints

Enter an alarm setpoint as follows:

1. Choose Alarm Setpoints on the Main Menu to display the Alarm Setpoints Screen (Figure 3-3).

2. Use the + or - keys to select weight and pressure within the highlighted char-acter field.The WEIGHT or PRESSURE field appears near the top of the Alarm Setpoints Screen.

3. Use the NEXT key to highlight the alarm value to be modified next to HIGH-HIGH, HIGH, LOW, or LOW-LOW.The character field to the right of the alarm parameter that the operator selects high-lights in reverse video to indicate it is active.

4. Press the MODIFY key to change the selected value.The Data-Entry Label Bar appears (Figure 3-4), and the digit cursor is displayed.

Figure 3-4. Data-Entry Label Bar on the Alarm Setpoints Screen

5. Use the DIGIT> key to move the digit cursor and highlight the digit to be mod-ified.

6. Use the INC or DEC keys to increment or decrement the selected digit.

7. Press the ENTER key to accept the desired value or Cancel to return the orig-inal value.




CHAPTER 3 Bulk Tank SystemDisplay Adjust Screen Manual XC-130

The number field containing the modified digit displays the new value in reverse video. The Data-Entry Label Bar changes back to the Item Label Bar (Figure 3-3).

8. Repeat Step 1 through Step 7 above to change other alarm setpoints, if neces-sary.

9. Press the EXIT key.The Main Menu appears (Figure 3-2).

3-3 Display Adjust ScreenUse the Display Adjust Screen (Figure 3-5) to adjust the backlight brightness, color, and contrast. The operator can set each of these numbers to any whole number between 0 and 99, where num-bers between 0 and 99 make a proportional change. For example, the number 50 sets the backlight brightness half-way between darkest and brightest.

Display Contrast Adjust Use the up-arrow key to darken screen contrast or the down arrow key to lighten screen contrast.

Backlight Brightness 0 is darkest; 99 is brightest.

Backlight Color 0 is green; 99 is red. (Adjust Backlight Color to red to avoid tem-porary night blindness.)

Slow Update Changes the screen update of the digital displays from 4 per sec-ond to 1 per 4 seconds. Bar graphs update at the same speed regardless. This feature is useful in extreme cold weather applica-tions where a slower update is necessary to compensate for slower screen responses.

Figure 3-5. Display Adjust Screen

3-3-1 Adjusting Display Contrast

1. Choose Display Adjust on the Main Menu to bring up the Display Adjust Screen (Figure 3-5).

2. Use the NEXT key to select Display Contrast Adjust.


Bulk Tank System CHAPTER 3Manual XC-130 Display Adjust Screen

Display Contrast Adjust highlights in reverse video to indicate it is active.

3. Use the INC or DEC keys to adjust the screen contrast.


3-3-2 Adjusting the Backlight Brightness


The Display Adjust Screen appears; the number field to the right of the Backlight Brightness item is highlighted in reverse video to indicate it is active.

2. Use the NEXT key to select Backlight Brightness.The number field to the right of the Backlight Brightness item is highlighted in reverse video to indicate it is active.

3. Press MODIFY to change the Backlight Brightness value.The Display Adjust Screen goes into configuration mode, the Data-Entry Label Bar appears (Figure 3-6), and the digit cursor is displayed.

Figure 3-6. Data-Entry Label Bar on the Display Adjust Screen

4. Use the DIGIT> key to move the digit cursor and highlight the digit to be mod-ified.


6. Press the ENTER key to accept the desired value.The number field containing the modified digit displays the new value in reverse video. The Backlight Brightness now conforms to the new setting. The Item Label Bar is redisplayed (Figure 3-5).


3-3-3 Adjusting the Backlight Color


The Display Adjust Screen appears.

2. Use the NEXT key to select Backlight Color.The number field to the right of the Backlight Color item is highlighted in reverse video to indicate it is active.

3. Press MODIFY to change the Backlight color value.




CHAPTER 3 Bulk Tank SystemGraph Scales Screen Manual XC-130

The Display Adjust Screen goes into configuration mode, the Data-Entry Label Bar appears (Figure 3-7), and the digit cursor is displayed.

Figure 3-7. Data-Entry Label Bar on the Display Adjust Screen

Use the DIGIT> key to move the digit cursor and highlight the digit to be modified.


5. Press the ENTER key to accept the desired value.The number field containing the modified digit displays the new value in reverse video. The LCD color conforms to the new screen setting. The Item Label Bar is redisplayed (Figure 3-5).


3-3-4 Adjusting the Slow Update


The Display Adjust Screen appears.

2. Use the NEXT key to select Slow Update.The field to the right of the Slow Update item is highlighted in reverse video to indi-cate it is active.

3. Use the INC or DEC keys to change the value from N to Y, or vice versa.


3-4 Graph Scales ScreenUse this screen to configure the bar-graph display on the Operator’s Screen for weight and pres-sure. The left scale value is the left side limit in the bar-graph range, and the right scale value is the right side limit in the bar-graph range.

Adjusting Graph Scales affects bar-graph displays only. It does not affect alarm operation or digi-tal readouts.

NOTEExchange the LEFT SCALE and RIGHT SCALE values to display graph-scale changes in the opposite direction.




Bulk Tank System CHAPTER 3Manual XC-130 Graph Scales Screen

Figure 3-8. Graph Scales Screen

3-4-1 Entering Graph Scale Values

The procedure for entering Graph Scale Values is as follows:

1. Choose Graph Scales on the Main Menu to bring up the Graph Scales Screen (Figure 3-8).

2. Use the + or - keys to select WEIGHT or PRESSURE.The weight or pressure label appears near the top of the Graph Scales Screen.

3. Use the NEXT key to highlight the LEFT SCALE or RIGHT SCALE value.

4. Press the MODIFY key.The Graph Scales Screen goes into configuration mode, the Data-entry Label Bar appears (Figure 3-9), and the digit cursor is displayed.

Figure 3-9. Data-Entry Label Bar on the Graph Scales Screen

5. Use the DIGIT> key to move the digit cursor and highlight the digit space to be modified.


7. Press the ENTER key to accept the desired value or CANCEL to return the original value. The number field containing the modified digit displays the new value in reverse video. The Data-entry Label Bar changes back to the Screen Label Bar (Figure 3-8).

8. Repeat the above procedure to change other Graph Scales, if necessary.





CHAPTER 3 Bulk Tank SystemCalibration Submenu Manual XC-130

3-5 Calibration SubmenuUse the Calibration submenu to check sensor calibration, calibrate sensors, and to calibrate analog-output modules. Highlight one of the following options using the NEXT button:

• Cal check• Two-point calibration• Data calibration• Analog-output calibration

Each of the above options is explained in the subsections that follow.

Choose Calibration on the Main Menu to bring up the Calibration Submenu (Figure 3-10).

Figure 3-10. Calibration Submenu

3-6 Cal Check ScreenUse the Cal Check Screen to engage remote calibration circuits through optional relays in order to verify weight-sensor calibration.

Figure 3-11. Cal Check Screen


Bulk Tank System CHAPTER 3Manual XC-130 Cal Check Screen

3-6-1 Verifying Weight-Sensor Calibration

Use the Cal Check Screen to energize remote shunt calibration circuits through optional relays as follows:

1. Press the CAL key on the Operator’s Screen.

The Cal Check Screen (Figure 3-11) appears with the CAL 1 status field highlighted in reverse video.

2. Press + or - to select ON or OFF.Select ON to energize remote shunt cal circuits and to OFF to deenergize remote shunt cal circuits. VERIFY WEIGHT value displays correct reading.

3. If the operator wishes to change the setting for Cal 2, press NEXT to select CAL 2.The selected data-entry field to the right of CAL 1 or CAL 2 highlights in reverse video to indicate it is active.

Press + or - to select ON or OFF.

Select ON to energize remote shunt cal circuits and to OFF to deenergize remote shunt cal circuits. Verify WEIGHT value displays correct reading.

3-6-2 Entering Numbers Into the Scratch Pad

Use the TARGET 1, TARGET 2 and SERIAL NO. fields in the Cal Check Screen to store weight calibration constants entered into the unit from Calibration Data Sheets or by CAL circuit demonstration. These values are visual references to compare with the CAL circuit WEIGHT value.

Use the Cal Check Screen to verify weight-sensor calibration as follows:

1. Press the CAL key on the Operator’s Screen.

The Cal Check Screen (Figure 3-11) appears with the CAL 1 character field high-lighted in reverse video.

2. Use the NEXT key to highlight the desired character field to the right of TAR-GET 1 or TARGET 2. or SERIAL NO.The character field that the operator selects highlights in reverse video to indicate it is active.

3. Press MODIFY.

NOTEThe TARGET1, TARGET2 and SERIAL NUMBER fields are for userconvenience only. The instrument has no “intelligence” regarding thesenumbers.


CHAPTER 3 Bulk Tank SystemTwo-Point Calibration Screen Manual XC-130

The Cal Check Screen goes into Configuration Mode, brings up the Configuration Label Bar (Figure 3-12), and displays the digit cursor.

Figure 3-12. Data-Entry Label Bar on the Cal Check Screen

4. Use the DIGIT> key to move the cursor to the digit space (one of seven) to be modified.The digit that the operator selects highlights in reverse video.

5. Use the INC and DEC keys to increase or decrease the highlighted digit.

6. Repeat Steps 4 and 5 as needed.

7. Press ENTER to store the value or CANCEL to abort the selection. Pressing either ENTER or CANCEL causes the Cal Check Screen to redisplay the Item Label Bar as in Figure 3-11.

8. Use NEXT to highlight another TARGET field or press EXIT to redisplay the Operator’s Screen.

3-7 Two-Point Calibration Screen Perform two-point calibrations by entering weight values appropriate for each weight sensor used. Low Cal Point represents the lowest value of load on the line (min load). High Cal Point represents the highest weight value (max load). These two points need not be zero or full scale, as any two points will work. But, for good accuracy, it is recommended that the two points be separated by at least 50% of full scale. For more information, see Appendix C. There are three methods of enter-ing two-point calibration:

• Physical load calibration for weight (Section 3-7-1)• Shunt calibration (remote calibration) (Section 3-7-2)• Voltage substitution calibration (Section 3-7-3)

Select the method to be used, and go to the appropriate section.




Bulk Tank System CHAPTER 3Manual XC-130 Two-Point Calibration Screen

Figure 3-13. Two-Point Calibration Screen

3-7-1 Physical Load Calibration for Weight

Use the Two-Point Calibration Screen to enter physical load as follows:

1. Navigate to the Two-Point Calibration screen:

Main Menu > Calibration > Two-Point Calibration

The Two-Point Calibration Screen (Figure 3-13) appears.

2. Use the + or - keys to select WEIGHT.

3. Use NEXT to highlight the Signal From item.

4. Use the + or - keys to select SENSOR next to the Signal From item.

5. Use the NEXT key to highlight the Low Cal Point character field.

6. Apply a known minimum load to the weight sensor.

7. Press MODIFY. The Data-Entry Label Bar (Figure 3-14) appears, and the digit cursor is displayed.

Figure 3-14. Data-entry Label Bar on the Two-Point Calibration Screen

8. Use the DIGIT> key to move the digit cursor to the digit space (one of seven) to be modified.

9. Use the INC and DEC keys to increment or decrement the highlighted digit.

10. Press ENTER to store the value or CANCEL to abort the selection. At this point, load on sensor is read (captured) and assigned to display the value entered.

11. The Item Label Bar reappears.

12. Use the NEXT key to highlight the High Cal Point character field


INC DEC



13. Apply a known maximum load to the weight sensor.

14. Press MODIFY.

15. The Data-Entry Label Bar (Figure 3-14) appears, and the digit cursor is dis-played.



18. Press ENTER to store the value or CANCEL to abort the selection. At this point, load on sensor is read (captured) and assigned to display the value entered.


20. Press EXIT to redisplay the Operator’s Screen.

3-7-2 Shunt Calibration (Remote Calibration)

Use the Two-Point Calibration Screen to do Shunt Calibration as follows:





3. Choose SENSOR next to the Signal From item.


5. Apply a zero load to the weight sensor.

6. Press MODIFY. The Two-Point Calibration Screen will show the Data-Entry Label Bar (Figure 3-15), and the digit cursor is displayed.


7. Key in the minimum value (usually zero) for the Low Cal Point on the screen; press ENTER.

8. Use the NEXT key to highlight the Signal From character field.

NOTEIt is very important to record the numbers shown for the offset and slopefor each sensor, after they are calibrated. Keep the recorded numbers in asecure place. They can be used to restore calibration if the unit’s data getscorrupted.


INC DEC


Bulk Tank System CHAPTER 3Manual XC-130 Two-Point Calibration Screen

9. Use the + or - keys to select CAL 1. This engages a Shunt Calibration circuit across the weight sensor.

10. Use the NEXT key to highlight the High Cal Point character field.

11. Press MODIFY.

12. The Two-Point Calibration Screen will show the Data-Entry Label Bar (Fig-ure 3-15), and the digit cursor is displayed.



15. Press ENTER to store the value or CANCEL to return the original value. At this point, load on sensor is read (captured) and assigned to display the value entered.


17. After the calibration is completed, be sure to enter Sensor in the Signal From character field.


3-7-3 Voltage Substitution Calibration

Use the Two-Point Calibration Screen to do voltage substitution as follows:





3. Use the NEXT key to highlight Signal From.

4. Use the + or - keys to highlight CAL 1.


6. Press MODIFY. The Data-entry Label Bar appears (Figure 3-16), and the cursor changes to the digit cursor.


7. To key in the appropriate weight value of the low weight standard for the Low Cal Point on the screen, use the DIGIT> key to move the digit cursor to the digit space (one of seven) to be modified.



INC DEC



9. Press ENTER to store the value and capture the Low Cal Point; press CAN-CEL to abort the selection. The Item Label Bar reappears.

10. Use the NEXT key to highlight the Signal From character field.

11. Use the + or - keys to select CAL 2.

12. Use the NEXT key to highlight the High Cal Point character field.

13. Press MODIFY. The Two-Point Calibration Screen will show the Data-Entry Label Bar (Figure 3-15), and the digit cursor is displayed.

14. To key in the maximum weight value of the high load standard for the High Cal Point on the screen.

15. Use the DIGIT> key to move the digit cursor to the digit space (one of seven) to be modified, use the INC and DEC keys to increment or decrement the highlighted digit.

16. Press ENTER to store the value and capture the High Cal Point; press CAN-CEL to abort the selection. At this point, load on sensor is read (captured) and assigned to display the value entered.

The Item Label Bar reappears.

17. After the calibration is completed, be sure to enter Sensor in the Signal From character field.



Bulk Tank System CHAPTER 3Manual XC-130 Data Calibration Screen

3-8 Data Calibration ScreenThe Data Calibration Screen provides the operator with a way to enter calibration factors directly (manual mode). For auto mode, use the Two-Point Calibration Screen.

Use the Data Calibration Screen to enter prerecorded calibration information if, for example, data is corrupted or lost.

Figure 3-17. Data Calibration Screen

The procedure for using the Data Calibration Screen is as follows:

1. Navigate to the Data Calibration Screen:

Main Menu > Calibration > Data Calibration

The Data Calibration Screen (Figure 3-17) appears.

2. Use the + or - keys to select WEIGHT or PRESSURE.

3. Press Next to select Offset.

4. Press Modify if changes are required (else press Next to go to Step 7).

The Data-Entry Label Bar appears (Figure 3-18), and the cursor changes to the digit cursor.

Figure 3-18. Data-entry Label Bar on the Data Calibration Screen

5. To enter the “offset” calibration factor, use DIGIT> to move the digit cursor and high-light the desired whole number digit position.

Use the INC and DEC keys to increment or decrement the number in the highlighted digit space.

6. Once the desired number is entered, press ENTER to store the value or CANCEL to return the original value.

7. Press Next to select Slope.

8. Press Modify if changes are required.


INC DEC


CHAPTER 3 Bulk Tank SystemAnalog-Output Calibration Screen Manual XC-130

The Data-Entry Label Bar appears (Figure 3-19), and the cursor changes to the digit cursor.

Figure 3-19. Data-entry Label Bar on the Data Calibration Screen

9. To enter the “slope” calibration factor, use DIGIT> to move the digit cursor and high-light the desired whole number digit position.

Use the INC and DEC keys to increment or decrement the number in the highlighted digit space.

10. Once the desired number is entered, press ENTER to store the value or CANCEL to return the original value.

11. Repeat Steps 2 - 10 for weight and pressure until all settings are correct.

12. Press Exit to return to the Cal Submenu.

3-9 Analog-Output Calibration Screen The primary purpose of calibrating the analog output modules is to make remote equipment, such as a meter, read the same as the values displayed by the Series 2000 instrument.

Calibrate the analog output of the option modules for weight and pressure using the Analog Output Calibration Submenu (Figure 3-20).

Figure 3-20. Analog Output Calibration Screen

In this screen, the left column represents display values; the right column represents the signal level at the output. The screen in Figure 3-20 shows that an output signal level of 47.9% is trans-mitted when the weight display value is 0 lbs. The output signal level of 87.2% is transmitted when the weight display value is 20,000 lbs. In general, the% output value is adjusted until the external device matches the display value (in the left column of Figure 3-20).

The input requirements of the external device will determine what type of analog output module you need and how to calibrate it. The analog output signal value is represented on the unit’s dis-play as a percentage. The relationship between this percent value and the value of the output signal (voltage or milliampere) depends on the type of module installed. Also, the exact value of the out-


INC DEC


Bulk Tank System CHAPTER 3Manual XC-130 Analog-Output Calibration Screen

put will differ slightly from unit to unit. Prior to connecting the output signal to the external device, you should set the output signal value (percent) to the nominal value. For example, if a dis-play of measured load from 0 to 20000 lbs must create an output signal of 0–10V, then set the ana-log output calibration screen as shown above in Figure 3-20. Refer to the following tables for nominal values for isolated and non-isolated analog output modules.

The procedure for using the Analog Output Calibration Screen is as follows:

1. Navigate to the Analog Output Calibration Screen:

Main Menu > Calibration > Analog Output Cal

The Analog Output Calibration Screen (Figure 3-20) appears.

2. Use the + or - keys to select WEIGHT or PRESSURE.

Table 3-1. Non-Isolated Analog Voltage Output

Voltage (V) Nominal Percentage (%)

-12.18 0

-10 8.6

-5 28.2

0 47.9

+5 67.5

+10 87.2

+13.27 100

Table 3-2. Non-Isolated Analog Current (Sourced) Output

Current (mA) Nominal Percentage (%)

0 0

4 18.3

12 55.0

20 91.7

21.8 100

Table 3-3. Isolated Analog Current (2-wire transmitter) Output

Current (mA) Nominal Percentage (%)

3.13 0

4 4.3

12 43.5

20 82.8

23.5 100


CHAPTER 3 Bulk Tank SystemAnalog-Output Calibration Screen Manual XC-130

3. Use the Next key to highlight the top value in the left column of the screen.

This number represents the display value for the point being calibrated.

4. Press Modify.

The Data-entry Label Bar appears (Figure 3-21), and the digit cursor is displayed.

Figure 3-21. Data-entry Label Bar on the Analog Output Cal Screen

5. Use DIGIT> to move the digit cursor and highlight the desired whole number digit position.

6. Use the INC and DEC keys to increment or decrement the number in the highlighted digit space.

7. Once the desired number is entered, press ENTER to store the value or Cancel to return the original value.

8. Use the Next key to highlight the top value in the right column of the screen.

This number represents the value of the output signal.

9. Press Modify.



11. Use the INC and DEC keys to increment or decrement the number in the highlighted digit space.

12. Once the desired number is entered and the external device exhibits the correct value, press ENTER to store the value or Cancel to return the original value.

13. Use the Next key to highlight the bottom value in the left column of the screen.

This number represents the display value for the point being calibrated.

14. Press Modify. The Data-entry Label Bar appears (Figure 3-21), and the digit cursor is displayed.


NOTEDuring this procedure, the output changes in real-time as you change the%-output value on the display. Change the value until the external devicereads the same value in the analog output calibration screen’s left column(if the external device is a display unit). Alternatively, change the “%output”value to achieve an accurate reading on an external current meter or voltmeter.


INC DEC


Bulk Tank System CHAPTER 3Manual XC-130 Analog-Output Calibration Screen

16. Use the INC and DEC keys to increment or decrement the number in the highlighted digit space. Make number selection based on the external display device or a digital mulitmeter.


18. Use the Next key to highlight the bottom value in the right column of the screen.

This number represents the value of the output signal.

19. To change this output value to match the unit’s corresponding displayed value, press Modify.



21. Use the INC and DEC keys to increment or decrement the number in the highlighted digit space. Make number selection based on the external display device or a digital mulitmeter.


23. Press EXIT to redisplay the Calibration Submenu.

NOTEDuring this procedure, the output changes in real-time as you change the%-output value on the display. Change the value until the external devicereads the same value in the analog output calibration screen’s left column(if the external device is a display unit). Alternatively, change the “%output”value to achieve an accurate reading on an external current meter or voltmeter.


CHAPTER 3 Bulk Tank SystemSystem Setup Menu Manual XC-130

3-10 System Setup MenuUse the System Setup Submenu (Figure 3-22) to display screens for setting:

• Operator Privileges• Units Of Measure• Relay Setup Options• Network Setup• Aux. Comm. Setup

Procedures for using each System Setup screen are in the sections that follow.

Figure 3-22. System Setup Submenu

3-10-1 Operator Privileges Screen

Each unit can be programmed to allow full operator access to calibration and configura-tion controls. It can also be programmed to deny operator access to any or all of these con-trols.

For example, a display station can be programmed so that the operator has access to changing the pressure value, acknowledging alarms, and selecting data presentation; how-ever, the operator can be denied access to calibration and system setup controls. Access to these controls is referred to as Operator Privileges.

The system is shipped with all privileges enabled (set to Y). After installation, privileges may be denied (set to N) as desired.

Use the Operator Privileges Screen as follows:

1. Navigate to the Operator Privileges Screen:

Main Menu > System Setup > Operator Privileges

NOTEAll privileges are accessible with the use of the product PASSWORD (eventhose set to N).


Bulk Tank System CHAPTER 3Manual XC-130 System Setup Menu

The Operator Privileges Screen (Figure 3-23) appears.

Figure 3-23. Operator Privileges Screen

2. Select the desired privilege using the Next key.The corresponding privilege (Y or N) highlights.

3. Use the + or - keys to change the selected privilege from Y to N as required.The highlighted privilege, Y or N, changes to its opposite.

4. Repeat the above procedure for each privilege to be changed.

5. Once the desired privileges have been entered, press EXIT.

3-10-2 Units of Measure Screen

Use the Units Of Measure Screen to choose the units of measure and precision for dis-played numbers of weight and pressure.

The precision can be set as a positive or negative number up to seven. Positive numbers define the decimal precision. For example, a precision of 0 means no decimal place is shown (the displayed number looks like xxx with no decimal point); a precision of 1 means xxx.x is shown; 2 means xxx.xx is shown; 3 means xxx.xxx is shown; and so forth. Negative numbers define how many digits are rounded off. For example, 0 means that all digits of the measured number are displayed (like xxxxx); -1 means the last digit is rounded to the nearest ten (like xxxx0), -2 means that the last two digits are rounded to the

NOTEIf the operator chooses N for System Setup, he will not be able to enterthe Operator Privileges Screen without a password.

CAUTIONUnits of measure are displayed text only. The calibration is NOT adjustedautomatically to follow the units. If units are changed, recalibration isrequired.



nearest hundred (like xxx00); -3 means that the last three digits are rounded to the nearest thousand (like xx000); and so forth.

The procedure for using the Units of Measure Screen is as follows:

1. Navigate to the Units of Measure Submenu:

Main Menu > System Setup > Units of Measure

The Units of Measure Submenu (Figure 3-24) appears.

Figure 3-24. Units of Measure Submenu

2. Use the + or - keys to select WEIGHT,or PRESSURE.

3. Press the Next key to select Units of Measure (LBS, KGS, KIPS, TONS).The corresponding character field highlights.

4. Use the + or - keys to select the appropriate units of measure to be displayed.

5. Press the Next key to select the PRECISION character field.

6. Press Modify (if a change is needed). Else go to Step 10.The Analog Units of Measure Submenu goes into configuration mode, the Data-entry Label Bar appears (Figure 3-25), and the cursor changes to the digit cursor.

Figure 3-25. Data-entry Label Bar on the Units of Measure Submenu


8. Use the INC and DEC keys to increment or decrement the number in the high-lighted digit space.


10. Press the Next key to highlight WEIGHT or PRESSURE.

11. Repeat Steps 2 through 8 until weight and pressure are configured.


INC DEC



12. Press Exit. The System Setup Submenu reappears (Figure 3-22).

3-10-3 Relay Setup Submenu

Use the Relay Setup Submenu to choose the alarm assignments and to determine what each relay does. Refer to Appendix B, Alarms and Relays, for more information.

The procedure for using the Relay Setup Submenu is as follows:

1. Navigate to the Relay Setup Submenu:

Main Menu > System Setup > Relay Setup

The Relay Setup Submenu (Figure 3-26) appears.

Figure 3-26. Relay Setup Submenu

2. Use the + or - keys to select Alarm Assignment or Relay Type.The operator’s selection highlights with a dark field to indicate it is active.

3. Press Select.The submenu corresponding with the operator’s selection, Alarm Assignments or Relay Type, appears.

CAUTIONIf Weight or Pressure units were changed, then recalibration is required.



3-10-3-1 Alarm Assignments Submenu

There are 8 alarm sources:

• Four setpoints for weight• Four setpoints for pressure

There are four relays (alarm destinations). The Alarm Assignments Screen is used to assign each alarm source to control any or all relays (or no relays).

Figure 3-27. Alarm Assignments Submenu

The procedure for using the Alarm Assignments Submenu is as follows:

1. Navigate to the Alarm Assignments Submenu:Main Menu > System Setup > Relay Setup > Alarm Assignments

The Alarm Assignments Submenu (Figure 3-27) appears.

2. Use the + or - keys to select WEIGHTor PRESSURE.

3. Press Next to select the HIGH-HIGH row, R1 column.The corresponding Y or N field highlights.

4. Use the + or - keys to turn the selected alarm assignment on or off (Y or N).The highlighted alarm, labeled Y or N, changes to its opposite.

5. Repeat Steps 2 through 4 for all four rows and columns.

6. Press Next to highlight the parameter (weight or pressure).

7. Repeat Steps 2 through 6 until all assignments are correct.

8. Press EXIT.

NEXT

Alarm Assignments

HIGH HIGH N N N N HIGH N N N N LOW N N N N LOW LOW N N N N

PRESSURE 1 R1 R2 R3 R4



3-10-3-2 Relay Type Submenu

Relays are controlled in one of six different ways, depending on the function (purpose) of the relay. The purpose of a relay is referred to as a relay type. Relay type refers to the way the instrument controls the relay; relay type does NOT refer to the type of physical relay installed.

The term “latched” means that once a signal exceeds an alarm setpoint, the relay will remain in the alarm state until it is acknowledged via the front panel. It has to be acknowledged even if the signal has returned to the normal range.

The term “unlatched” means that the relay will reflect the present signal value; it does not need to be acknowledged.

Use the Relay Type Submenu to tell the unit how to control each relay. The relay positions (Relays 1 to 4) are in the left column of the screen and the relay types are in the right column. Refer to Appendix B for more information on relays.

The procedure for using the Relay Type Submenu is as follows:

1. Choose Relay Type from the Relay Setup Submenu.The Relay Type Submenu (Figure 3-28) appears.

Figure 3-28. Relay Type Submenu

2. Use the + or - keys until the desired relay type appears high-lighted. Possible relay type selections are:



• Latched Horn• Latched Relay• Unlatched Horn• Unlatched Relay • Remote Cal 1• Remote Cal 2Horn relays are normally deenergized. General purpose relays are nor-mally energized so that they will fail-safe in their alarm mode if power is lost.

3. Press the NEXT key to go to another relay if necessary.The corresponding Relay Type field highlights.

4. Repeat Steps 2 and 3 until all settings are correct.

5. Press the EXIT key.The System Setup Submenu reappears (Figure 3-22).

3-10-4 Network Setup Screen

Use the Network Setup Screen to designate a unit as a sensor input or remote display unit.

For units designated as Sensor Input Units, it is necessary to set the rotary switch on the back of the unit until the first unit reads “1” on the Rotary Switch field of the Network Setup screen. Then use the rotary switch to set each succeeding unit such that each unit has a unique number.

For units designated as Remote Displays, it is necessary to select the Remote Display number in the first field of the Network Setup Screen. Then use the rotary switch to match the winch number that will most often be displayed by this remote. In the Operator’s Screen, select the winch number to be displayed now. For more information on network setup, refer to Appendix G.

3-10-4-1 Configuring the Instrument as a Sensor Input Unit

The procedure for configuring a unit as a Sensor Input Unit is as follows:

1. Navigate to the Network Setup Screen:Main Menu > System Setup > Network Setup



The Network Setup Screen (Figure 3-29) appears.

Figure 3-29. Network Setup Screen

2. Use the + or - keys until the top field reads SENSOR INPUT UNIT.The top field reads Sensor Input Unit highlighted in reverse video.

3. Adjust the rotary switch on the back of the unit to the appropriate setting.The number to the right of the Rotary Switch label reflects the current rotary switch setting.


3-10-4-2 Configuring the Instrument as a Remote Display Unit

The procedure for configuring a unit as a Remote Display Unit is as follows:

1. Navigate to the Network Setup Screen:Main Menu > System Setup > Network Setup

The Network Setup Screen (Figure 3-29) appears.

2. Use the + or - keys until the top field reads REMOTE DISPLAY #, where # stands for the appropriate display number. The top field reads REMOTE DISPLAY #, highlighted in reverse video.

3. Adjust the rotary switch on the back of the unit to the setting of the most commonly viewed winch number for this remote dis-play.The number to the right of the Rotary Switch label reflects the current rotary switch setting.




3-10-5 Aux. Comm. Setup Screen

Use the Aux. Comm. Setup Screen to configure serial communications to a customer computer or other device via RS-232 or RS-485 option modules. Possible configurations via the Aux. Comm. Setup Screen are:

• Choosing the protocol• Changing the data interval• Changing the data-transmission baud rate• Enabling or disabling parity• Choosing even or odd parity

Use the Aux. Comm. Setup Screen as follows:

1. Navigate to the Aux. Comm. Setup Screen:

Main Menu > System Setup > Aux. Comm. Setup

The Aux. Comm. Setup Screen (Figure 3-30) appears.

Figure 3-30. Aux. Comm. Setup Screen

2. Press Modify.The Data-entry Label Bar appears (Figure 3-31), and the digit cursor is displayed.

Figure 3-31. Data-entry Label Bar on the Aux. Comm. Setup Screen

NOTEThe default number in the Data Interval (1/4 Sec) character field is 4. (Asetting of 1 means that data is transmitted every 1/4 sec; a setting of 4means that data is transmitted every second; 8 = every 2 sec, etc.).


INC DEC



3. To change the data interval, use DIGIT> to move the digit cursor and highlight the desired whole number digit position. Use the INC and DEC keys to increment or decrement the number in the highlighted digit space.

4. Once the desired number is entered, press ENTER to store the value or CAN-CEL to return to the original value.

5. Press the NEXT key to highlight the PROTOCOL character field.

6. Use the + or - keys to scroll through the protocol choices (1, 2, or continuous mode).

7. Press the NEXT key to highlight the DELIMITER character field.

8. Use the + or - keys to scroll through the delimiter choices (comma, space, or tab).

9. Press the NEXT key to highlight the BAUD character field.9600 baud is the default.

10. Use the + or - keys to scroll through the baud-rate choices (9600, 19.2K, 300, 600, 1200, 2400, 4800).

11. Use the NEXT key to highlight the Parity Enabled? character field.

12. Use the + or - keys to choose Y for Yes or N for No.N is the default.

13. Use the NEXT key to move the highlight to the Odd Parity? character field.

14. Use the + or - keys to choose Y for Yes or N for No.N is the default. (Yes = odd, No = Even.)

15. Press EXIT to return to the Main Menu.

NOTEIf Parity Enable = No, then this field is ignored.




CHAPTER 4TROUBLESHOOTING, DIAGNOSTICS, AND

MAINTENANCE

4-1 OverviewThere are three types of diagnostics available on Series 2000 Instruments:

• Power-On Self Test—test routines that the unit runs to test its internal subsystems. These tests are performed at power up and after reset during normal operation.

• Run Time Background Tests—test routines that run automatically during normal operation that detect and record errors in the entire system. This includes creating error logs.

• Troubleshooting Diagnostics—tools that allow you to view the raw sensor data. By changing the value of the signal that is input to the unit, you can look for the expected changes in the raw data. These diagnostics also control output devices such as relays and analog outputs.

4-2 Navigating the MenusFigure 5-1 is a menu tree that shows the navigation routes from the Operator’s Screen to the Diag-nostic Menu.

Figure 4-1. Navigation Route from Operator’s Screen to Diagnostics Menu

AlarmSetpoints

press the + key

RawCounts

PowerSupplies

ErrorLogs

SelfTests

Relays OptionsSPI

Diagnostics

LocalHardware

Errors

LocalNetworkErrors

PerformSelfTests

SelfTest

Results

press the + key


CHAPTER 4 Bulk Tank SystemDiagnostic Menus Manual XC-130

4-3 Diagnostic MenusThe following subsections describe the individual diagnostic menus and examples of their use in troubleshooting.

4-3-1 Raw Counts (troubleshooting diagnostic)

The raw counts screen presents you with a list of the various inputs and the raw sensor data. By substituting a signal generator set to mimic the input in question, you can alter the input and look for the expected change in the raw counts displayed..

Figure 4-2. Raw Counts Display

4-3-2 Power Supplies (run time background)

Selecting this menu item shows you a value representing each power supply in the unit. If these values are outside the following acceptable ranges, there may be a problem with the power supply circuit.

Power Supply Acceptable Range

-15 V 115–145

+15 V 90–115

+24 V 150–180

+3.84 215–240

4mA≈10,50020mA≈52,400

24,000–42,000

Acceptable Ranges


Bulk Tank System CHAPTER 4Manual XC-130 Diagnostic Menus

4-3-3 Error Logs (troubleshooting diagnostic)

Figure 4-3. Error Log Menu for a Remote Display

Figure 4-4. Error Log Menu for a Sensor Display

Notice that the remote display’s screen is slightly different than the sensor display. It includes information on sensor unit errors as well as remote unit errors.

Each unit keeps a count of errors it senses during operation. If there seems to be some kind of problem during operation, check the error logs to narrow down where the problem might be. Select an error log by pressing the →=key to highlight it, and then press the ↵ =key.



4-3-3-1 Local (or Sensor) Network Errors

After selecting Local (or Sensor) Network error log, you will be presented with a screen similar to the following:

Figure 4-5. Local Network Error Log Screen for a Sensor

• Recv CRC errors—number of times the system has detected errors in CRC of records coming in from the network.

• Recv sync errors—number of times the system has detected an unexpected sync character in a record.

• Buffers full—number of times the buffer was full when it needed to receive a record from the network.

• UART Errors—number of errors generated by the UART pro-cessor interface.

• Search Mode—number of times the system has been put into search mode.

• Timeouts—number of times the system has not received a response from a device it has sent a request to.



4-3-3-2 Local (or Sensor) Hardware Errors

Depending on whether the unit is acting as a sensor or a remote, a screen similar to the following will be presented:

Figure 4-6. Hardware Error Log for a Sensor Unit

• ADC Data Ready Errors—number of times the ADC has failed to convert data within its allotted time.

• ADC Cal Errors—number of times the ADC failed to calibrate a channel.

• -15 VDC—number of failures recorded from this power supply.• +15 VDC—number of failures recorded from this power supply.• +24 VDC—number of failures recorded from this power supply.• +3.84 VDC—number of failures recorded from this power supply.



4-3-4 Self Tests

In the diagnostic menu, select self test. The display will present you with the following menu:

Figure 4-7. Self Test Menu

Highlight the desired menu item using the → key, then press the ↵ key.

4-3-4-1 Self Test Results

The first time you select this self test option after power up, it will show you the results of the self tests it ran at power up. Each time thereafter it will show you the results of the last batch of self tests it ran. Self test results are broken down into those for the sensor components and those for the display components.

Figure 4-8. Self Test Results Screen

The following is a description of what each of the self tests report.



• RAM—results of a read/write test to the random access memory for both the display and sensor. If either reading or writing errors occur, it will record this as "FAIL".

• Program—results of a checksum test on the display and sensor EPROM. Software programs are stored here.

• EEPROM—results of a checksum test on the display and sensor EEPROM. Calibration and configuration information are stored here.

• ZRAM/Bank—results of a checksum test run on the sensor ZRAM and on the display processor EPROM. ZRAM (sensor) holds payout value and less critical configuration data. Bank holds display software data.

• -15 VDC—results of check to see if power supply is working within tolerance.

• +15 VDC—results of check to see if power supply is working within tolerance.

• +24 VDC—results of check to see if power supply is working within tolerance.

• +3.84 VDC—results of check to see if power supply is working within tolerance.

• ADC/Temperature—results of a check of the analog to digital con-verter and the internal temperature of the enclosure. If the result is FAIL, check the temperature raw count diagnostic. If the raw count of the temperature is between 24,000–42,000 it means that the ADC failed the test. If the temperature is outside 24,000–42,000 it most likely means that the FAIL message is for temperature problems.

• Encoder—results of a diagnostic test of the circuit that monitors the payout/position sensor.

4-3-4-2 Perform Self Tests

Selecting this diagnostic resets the unit and puts it through start-up and self test, but keeps the alarm settings and graph scaling in memory. By performing the self test, it also updates the self test results.

4-3-4-3 Load Factory Defaults

This diagnostic tool is useful for rebuilding a setup from scratch.

WARNING

This option resets all settings to their factory defaults. Any changes madeto the screen configuration, scaling, alarm setpoints, calibrations, etc. willbe erased and replaced with the factory settings.



4-3-5 Relays-Alarms Disabled

This diagnostic allows you to activate/deactivate relays to ensure proper operation.

Figure 4-9. Relays-Alarms Disabled Screen

Once you have selected this option, use the → key to select the relay you want to toggle on/off, and then press the + or - keys to toggle the relay.

4-3-6 Options (troubleshooting diagnostic)

This diagnostic allows you to test any analog output modules installed on the unit. It applies a known value (scaled in %) to the analog output module, allowing you to look for the appropriate response from the module.

Figure 4-10. Options Diagnostic Screen

WARNING

This test procedure disables system alarm checking. This means that alarmconditions sensed while toggling the relays on and off will not generate analarm in the system.


Bulk Tank System CHAPTER 4Manual XC-130 Software Update Procedure

4-3-7 SPI Diagnostics (run-time background)

This diagnostic tool tracks the communication between processors inside the unit, and keeps a running count of the errors it detects.

Figure 4-11. SPI Diagnostic Screen

• Recv CRC errors—# of errors detected in records sent between proces-sors.

• Collisions—number of times two or more peripherals tried to transmit info on the SPI bus at the same time.

• Xmit NAK—number of responses to records received in error over SPI bus.

• Recv sync errors—number of times an unexpected sync character was detected in a record received over the SPI bus.

• Buffers full—number of times a buffer was full when it needed to receive information over the SPI bus.

4-4 Software Update ProcedureThe following are the steps involved in changing the firmware chips (software) in Series 2000 instruments. Refer to the assembly drawing (dwg # 220870) for visual information to supplement these instructions. Note the following conventions used in the assembly drawing: a circle with a number in it refers to an item number in the parts list, a square with a number in it refers to a note for assemblers.

1. Record all calibration and installation parameters before attempting any changes to the software.

2. Remove the six black screws from the rear cover (items 8 and 9).

3. Remove the rear cover (item 7) and the field wiring board (item 6). Note that the field wiring board includes all of the terminal blocks, and is connected to the main board only by the plug-in connector described in note 4, meaning there is no need to remove the wires to access the main board and software.


CHAPTER 4 Bulk Tank SystemSoftware Update Procedure Manual XC-130

4. Refer to view A of the 220870 drawing and locate the following EPROM’s: U10, U27, and U30. Carefully pry the EPROM’s from their sockets.

5. Gently place each new EPROM into its correct socket. Each EPROM is labeled U10, U27, or U30. The chip MUST be oriented properly so that pin #1 is in the correct loca-tion. Note that one end has a dot over pin #1 and a notched or chamfered corner. If there is any question, remember. . . IF THE CHIP IS INSTALLED BACK-WARDS, IT WILL BE DESTROYED. Once properly aligned, press firmly to seat the chip in place.

6. Replace the field wiring board, rear cover and wiring. Be sure that the connector is properly aligned and press it into place. Replace the six black screws.

7. Power the unit up and allow it to go through selftest.

Initialize the software as follows:

1. Press the F1 key. Wait one second. (The alarm screen is displayed.)

2. Press the F2 key. Wait one second. (The display does not change.)

3. Press the F3 key. Wait one second. (The display does not change.)

4. Press the F4 key. Wait one second. (An initialization screen is displayed.)

5. Press the NEXT key. (The cursor moves to the number field.)

6. Press MODIFY. (The unit enters the data entry mode.)

7. Press DIGIT>. (The cursor moves one space to the right.)

8. Enter the product initialization code using the DIGIT>, INC, or DEC buttons as required.The code for the display for Tanks 1 and 2 (mud/cement) is 3113.The code for the display for Tanks 3 and 4 (mud/cement) is 3223.The code for the display for Surge Tanks 1 and 2 is 3369.When the correct number is displayed, then press CONFIG. (Consult the factory for the initialization code.)

9. WAIT 10 SECONDS.

10. Turn the power off for 5 seconds.

11. Turn the power back on. The unit should now be ready for operation. Verify that all calibration constants and configuration parameters are correct.

WARNING

This unit can be damaged by static electricity. If a static controlled workstation is not available, always keep one hand touching one of the six metalhex-shaped standoffs the entire time the rear cover is removed. This willhelp avoid static build-up.


Bulk Tank System CHAPTER 4Manual XC-130 Error Symbols

4-5 Error SymbolsThe following table lists the various error symbols that an S-2000 instrument can display, their meaning, and their possible causes.

4-6 Periodic MaintenanceThe bulk tank system is designed to minimize maintenance. In order for this to this to be effective as possible the user must follow the following two procedures:

• Voltage Substitution Calibration (see Chapter 3, section 3-7-3)• Verify mimic LED light are functional. To do this activate the test button once a

week.

Table 4-1. Error Symbols

Displayed Data Meaning Possible Cause

///////

Display CPU not receiving current valuesSPI communication failed

ADC in self-calibration

Invalid data

Sensor channel not configured

Algorithm not defined

Divide by 0 error

No DRDY from ADC

/-----/ + or - infinityNo DRDY from ADC

Format conversion error (bad data)

-------Data doesn’t fit in display field (>7 digits) Value < -999999

Remote display not receiving current val-ues from sensor input display

Selected sensor unit not on-line

/-/-/-/ Data doesn’t fit in display field (>7 digits) Value > 9999999


CHAPTER 4 Bulk Tank SystemPeriodic Maintenance Manual XC-130


APPENDIX AGLOSSARY

A-1 Special Terms, Acronyms, and AbbreviationsAlarm A condition reached when a measured parameter exceeds or goes below

operator defined normal operating limits.

LCD Liquid-Crystal Display

LED Light-Emitting Diode

Label Bar A display just above the keypad which shows the function of each key. The keys in the keypad can have different functions in different levels of the menu and screen hierarchy.

Load Cell A type of sensor.

Menu A display of options that allows the operator to change system values or to navigate to a screen or a submenu.

N.C. Normally Closed or Not Connected

N.O. Normally Open

Navigation Moving through the hierarchy of menus, submenus, and screens by pressing the keys below the display.

Networking Connecting two or more instruments together with RS-485 communications links so that the operator can view the information from a remote display.

Operator’s Screen This is the default operating screen. The operator can choose from several different screen layouts to optimize parameter viewing.

RS-232 Recommended Standard 232. Describes the signal function and voltage lev-els of a communication standard. Typically used by PCs.

RS-485 Recommended Standard 485. Describes the signal function and voltage lev-els of a communication standard. Typically used in party-line (or multi-drop) communications.

Reverse Video A convention to indicate a menu item is selected and active. In reverse video, what is normally white on the LCD changes to black, and what is normally black changes to white.

Screen Displayed image format on the front of the instrument.

August 19, 1999 Page A-1M/D TOTCO

APPENDIX A Bulk Tank SystemSpecial Terms, Acronyms, and Abbreviations Manual XC-130

Page A-2 August 19, 1999M/D TOTCO

APPENDIX BALARMS AND RELAYS

B-1 OverviewThe purpose of this Appendix is to describe the alarm and relay characteristics for theM/D TOTCO Series 2000 instrument family. Items discussed include contact types, software con-trol of relays, alarm operation, and functions accessible from the front panel of the instrument.

Series 2000 instruments are equipped with 4 relay sockets. Optional relays can be installed in these sockets for alarm or calibration purposes. The sockets can accept various types of relays, as described below. Programming of the relays is achieved using the keys below the display.

B-2 Relay Contact TypesWhen using Series 2000 instruments, various combinations of contact types and ratings are avail-able. These include "pilot" relays with 10 VA contact ratings, multi-purpose relays with 125 VA contact ratings, and special high power relays with 1250 VA contact ratings. Solid state relays with 2 amp contact ratings are also available. The following subsections describe the different styles of contacts.

B-2-1 Normally Open Contacts vs. Normally Closed Contacts

There are three basic contact styles:

• Form-A contacts are normally open (N.O.); energizing the coil closes the con-tacts.

• Form-B contacts are normally closed (N.C.); energizing the coil opens the contacts.

Form-A

de-energized energized

Form-B


August 19, 1999 Page B-1M/D TOTCO

APPENDIX B Bulk Tank SystemHorn vs. Relay Manual XC-130

• Form-C contacts act like a single pole, double throw (SPDT) switch. Internal to this type of contact is both a normally open and a normally closed contact, and a common. The Series 2000 does not have a Form-C contact; instead, a relay can be installed that has both a Form-A and a Form-B contact (Form-1A/1B). This is more flexible because you can wire it to behave like a Form-C, or use it as two separate contacts.

B-2-2 Mechanical Contacts vs. Solid State Contacts

Series 2000 instruments can use either solid state or mechanical contacts, except in haz-ardous (Div 2) applications where only solid state relays are allowed.

B-3 Horn vs. RelayFor Series 2000 instruments, relays are lumped into three general types:

• Horn Relays• General-Purpose Relays• Cal Relays

The following subsections describe the ways in which the software controls the relays. Please note, however, that this information pertains only to software control, not the relays themselves.

NOTEWhen choosing a solid state relay, you must know what kind of power thecontact will be switching. Solid state relays for AC power are NOTinterchangeable with solid state relays for DC power.

Form-C

commonnormally closed (N.C.)

normally open (N.O.)


Form-1A/1B (wired as a Form-C)

Form A

Form B

Form A

Form B

Page B-2 August 19, 1999M/D TOTCO

Bulk Tank System APPENDIX BManual XC-130 Horn vs. Relay

B-3-1 Fail-safe vs. De-energized

Fail-safe control of a relay means that the coil is held energized during normal operation; the coil is released (de-energized) during alarm conditions. This means that if power to the instrument fails, the relay will go to the alarm condition.

B-3-2 Horn Relay vs. General-Purpose Relay

Each kind of relay can be programmed to specifically control an external horn or to be used as a general-purpose alarm relay.

HORN—relays meant specifically to control external horns. These relays are de-ener-gized during normal operation, and energize when in an alarm condition. They are imme-diately de-energized when the ACK button is pressed. The operator is then given the option to clear the general purpose relays.

RELAY—meant for general purpose alarm use, and are controlled fail-safe.

B-3-3 Latched vs. Unlatched

Each relay, horn or general-purpose, can be programmed to operate latched or unlatched.

LATCHED—relays and horns that must be manually acknowledged via the front panel of Series 2000 instruments. This means that if the alarm condition goes away, the horns and relays stay in the alarm condition until they are manually cleared.

UNLATCHED—relays or horns that are self-acknowledging. If the alarm condition goes away, then the relays clear and the horns (if any) silence automatically.

B-3-4 Cal Relays

These are special purpose relays meant for controlling calibration circuits in external sig-nal conditioners. Up to two cal relays can be programmed via the front panel. In applica-tions that use shunt calibration, only one cal relay is needed. This relay is normally installed in relay socket 4 on the back of a Series 2000 instrument. In applications using voltage substitution, both cal relays must be used.

On strain gauge input versions of Series 2000 instruments, there is one cal relay built into the system internally, in addition to the 4 external relays on the back of the unit. This built in relay has two normally open contacts. When these contacts are closed, they can activate two shuntcal resistors located on the terminal blocks on the rear of the unit.

NOTEFail-safe describes the way the coil of the relay is controlled; it has nothingto do with the contacts of the relay being normally open or normally closed.

NOTECal relays take up space that could otherwise be used for alarm relays. Ifa relay socket is defined as a cal relay, that socket cannot be used for anyother purpose until the unit is reprogrammed.


APPENDIX B Bulk Tank SystemAlarm Operation Manual XC-130

B-4 Alarm OperationEach measured or calculated channel has four alarm setpoints (2 high & 2 low). Each setpoint is individually programmed via the front panel. Each alarm source can be individually assigned to one or multiple relays. It is also possible to assign multiple alarm sources to a single relay.

TRI-COLOR LED—located on the front of the display, second from the left. The different colors of the LED represent differing levels of alarm.

• Green (normal operation)= no alarm • Yellow (caution)= at least one alarm source is in low or high alarm • Red (overload)= at least one alarm source is in high-high or low-low alarm

FLASHING DIGITS—when a particular parameter goes into alarm condition, the digits display-ing the value of the parameter on the display start flashing. They flash even if the alarm is acknowledged, and only stop flashing when the alarm condition goes away.

AUDIBLE BEEP—sounds when at least one alarm source is in low or high alarm condition. The beep is silenced by pressing the ACK button, or when all of the alarm conditions are gone.

AUX COMM ALARM STATUS CHARACTERS—the alarm status of each parameter is also transmitted on the aux comm data package. Refer to the aux comm protocol for more information.

RELAYS—react as programmed to indicate alarm conditions.

ACK & SILENCE—front panel button that ACKnowledges alarms. Pressing this button during alarm conditions silences the audible beep and resets all relays programmed as horns. The operator has two choices: continue with no further change or clear all general purpose relays and continue.

B-5 Alarm and Relay Programming via the Front PanelAlarm assignments and relay programming are accomplished through the front panel of Series 2000 instruments.

B-5-1 Alarm Assignments

Each alarm source can be assigned to control any or all alarm destinations (in any combi-nation desired):

Alarm Sources (for each parameter) Alarm Destinations

High-High (overload)Relay 1

High (caution/approach)Relay 2

Low Relay 3

Low-Low Relay 4

A setpoint value for each of these alarm sources can be entered via the front panel.

CAUTIONThe audible beep on Series 2000 instruments is not meant to be used asa warning device in industrial environments because it is not loud enoughto serve that purpose. Its primary purpose is to provide audio feedback forkey presses.


Bulk Tank System APPENDIX BManual XC-130 Tips and Hints

B-5-2 Relay Types

Relay functions must be selected via the front panel of Series 2000 instruments, with six relay types to choose from. This selection determines the way the software controls the relay; it does NOT refer to the type of physical relay installed. The choices are as follows:

UNLATCHED HORN—meant to drive external horns

LATCHED HORN—meant to drive external horns

UNLATCHED RELAY—fail-safe control of general purpose alarm relay

LATCHED RELAY—fail-safe control of general purpose alarm relay

CAL 1—meant to control external calibration circuits

CAL 2—meant to control external calibration circuits

B-6 Tips and Hints1. Use assignments that come as close to matching the default assignments as possible.

For example, shuntcal relays are installed in relay socket 4, horns are defaulted to relay 1. Keep these assignments if possible.

2. General purpose relays are run fail-safe. This means that the actual relay contacts installed should have the opposite logic of what is desired in the system. For example, when a Form-A contact is controlled by the software as fail-safe, it will be closed in normal operations, and open in alarm conditions. Likewise, if a Form-B contact is controlled by the software as fail-safe, it will be open during normal operations, and closed in alarm conditions.

3. The Gx2-1amp5-AB-LC relay (P/N 927003-007) has both Form-A and Form-B con-tacts (a Form-1A/1B). This offers the most flexibility in the system.


APPENDIX B Bulk Tank SystemTips and Hints Manual XC-130

The diagram above shows how a Series 2000 instrument reacts to changes in load value over time. The darkened bars represent the “on” or “activated” condition of a component.


APPENDIX CSTRAIN GAUGE SENSOR CALIBRATION TECH-

NIQUES

C-1 OverviewThere are four recommended techniques for calibrating strain gauge sensors:

• Physical Calibration—calibrates the sensor with an accurately known load• Shunt Calibration (Shuntcal)—shunts one leg of the strain gauge bridge with a

precision resistor• Voltage Substitution—substitutes the entire strain gauge bridge with a precision

resistor divider in order to produce a specific mV/V value• Bridge Substitution—same as voltage substitution, only the strain gauge bridge is

used as part of the resistor dividerPhysical calibration is the most desirable technique because it takes into account all possible parts of an installation by directly loading the sensor. However, many applications will not allow for a physical calibration, which means that the sensor will have to be calibrated using simulated loads.

Each of the calibration techniques described in the following sections assumes the sensor reacts in a linear fashion to increasing load. This means that the calibration techniques are all of a 2-point variety, with the two points defining the linear response of the sensor.

As with any 2-point calibration, the farther apart the data points are, the more accurate the calibra-tion. As a general rule, try to take one data point from somewhere less than 25% of total capacity, and a data point from somewhere above 75% capacity.

C-2 Physical CalibrationCalibration is done by applying an accurately known load to the system, and adjusting the display to match the known load value. It is recommended that every installation get a physical calibration at least once, preferably at commissioning.

C-2-1 Physical Calibration Procedure

1. Remove all load from the system so that the system is in a condition where the measured value on the display should read zero. Although the low cal point doesn’t need to be zero, zero is often the easiest data point to obtain.

2. Adjust the display to read zero.

3. Apply a known physical load.

4. Adjust the display to read the actual value of the known load.

5. Remove the load and verify that the display reads zero again.

6. Activate each calibration circuit in the system (shuntcal, voltage substitution, bridge substitution) and record the values of each for future reference.

August 19, 1999 Page C-1M/D TOTCO

APPENDIX C Bulk Tank SystemShunt Calibration (Shuntcal) Manual XC-130

C-3 Shunt Calibration (Shuntcal)Calibration is done by shunting one leg of the strain gauge bridge, (-) excitation to (-) signal, with a precision resistor, see Figure C-1. This creates a repeatable change in the output signal of the load cell. The actual value depends on the value of the resistor and the resistance of the strain gauge bridge.

Figure C-1. Shunt Calibration Diagram

Shuntcal is a relative calibration, creating a known ∆ (change) in the output. For example, assume that the shuntcal value for a given application is 80%. If the load displayed prior to activating the shuntcal switch is 12%, then the display should read 92% after activating the shuntcal circuit. This change depends on the value of the resistor and the resistance of the bridge itself. Refer to the fol-lowing table:

+EX

- EX

+Sig-Sig

Shuntcal Resistor

Shuntcal Switch

Page C-2 August 19, 1999M/D TOTCO

Bulk Tank System APPENDIX CManual XC-130 Shunt Calibration (Shuntcal)

C-3-1 Shuntcal Procedure

1. Remove all load so that the system is in the condition where the measured value is zero (or as close to zero as possible).

2. Adjust the display to read zero (or the known minimum load).

3. Activate shuntcal and adjust the display to read the value that was recorded when the shuntcal circuit was activated during physical calibration (plus any minimum load present from the step above). If no previous physical calibra-tion was performed, use the shuntcal value from the load cell calibration cer-tificate.

4. Deactivate shuntcal and verify that the display reads zero (or the known mini-mum load again).

Table C-1. Shuntcal Value Approximations

Bridge (Ω)

Full Scale (mV/V)

ShuntCal Resistor (Ω)

Approx. Output (mV/V)

175 1.0 50K 0.87

175 2.0 25K 1.74

350 1.0 100K 0.87

350 1.5 75K 1.16

350 2.0 50K 1.74

350 3.0 34.14K 2.55

700 1.0 200K 0.87

700 1.5 150K 1.16

700 2.0 100K 1.74

700 3.0 75K 2.32

NOTEThe output of each individual load cell is recorded during its factorycalibration. These output values are supplied on the Calibration Certificatethat accompanies each load cell from the factory. Shuntcal resistor anddata are not automatically supplied with all sensors and must be specificallyordered with the system.

NOTEThe value on the calibration certificate refers to the actual load applied tothe load cell, not necessarily the measured load shown on the display.


APPENDIX C Bulk Tank SystemVoltage Substitution Manual XC-130

C-4 Voltage SubstitutionThis method of calibration replaces the load cell’s strain gauge bridge with a precision resistor divider. The divider consists of three resistors in series with excitation applied to the endpoints, and the signal read off the center resistor. See Figure C-2.

Figure C-2. Resistor Divider for Voltage Substitution Calibration

(resistor values shown as examples only)

Depending on the values of the divider’s resistors, any "mV/V" value can be created. The center resistor has a much smaller value than the other two, and the low cal point center resistor has a small value compared to the high cal point center resistor. If the low cal point center resistor is actually a short between +Sig and -Sig, then a true 0.0 mV/V value is applied. Two separate divid-ers give you the high and low calibration points.

Voltage substitution creates a specific mV/V value that is independent of the load on the load cell. This makes it a popular calibration technique for those applications where the load cell is a struc-tural load-bearing member, when the load cell is monitoring mooring lines for large permanent structures, or any time load cannot be removed for calibration.

C-4-1 Voltage Substitution Procedure

1. Obtain the records of the first physical calibration of the load cell, and look up the values recorded for the voltage substitution check done at that time. If this information is unavailable, obtain the calibration certificate that came from

+EX

- EX

+Sig

-Sig

500R

R

500R

+EX

- EX

+Sig

-Sig

500R

0.1R

500R

High Cal Point Divider Low Cal Point Divider


Bulk Tank System APPENDIX CManual XC-130 Voltage Substitution

the factory with the load cell, and see if it has specially recorded cal factors for voltage substitution.

2. Activate the Low Cal Point and adjust the display to match the value specified on the documents listed in step 1.

3. Deactivate the Low Cal Point.

4. Activate the High Cal Point and adjust the display to match the value speci-fied on the documents listed in step 1.

5. Deactivate the High Cal Point.

6. Activate the Low Cal Point again and verify that the displayed value is the same as it was at the end of step 2.

In some cases, the values substituted are zero and full scale. This can create problems if the instrumentation does not have sufficient headroom below zero and above full scale. This headroom is required as a result of tare loads and load cell output tolerances. In cases where this is a concern, mV/V values can be chosen that will prevent this from being a problem. For example, the substituted values can be approximately 15% and 90% of full scale. This creates sufficient headroom even in cases where the instrumentation cannot display values below zero or above full scale.

As a troubleshooting tool, this method verifies all circuits from the signal conditioner input through the display. It does not verify the load cell or the load cell wiring.

CAUTIONThe values on the calibration certificate pertain to load on the load cell, anddo not take into account any tare load (zero offset).

NOTEZero offset cal factors are not routinely recorded on the calibrationcertificate, except when specifically requested on special "turn-key"systems.


APPENDIX C Bulk Tank SystemBridge Substitution Manual XC-130

C-5 Bridge SubstitutionThis calibration method is similar to voltage substitution, except that the center resistor in the resistor divider is the strain gauge bridge itself. See Figure C-3.

Figure C-3. Resistor Divider for Bridge Substitution Calibration

The advantages of this method are that it checks the two signal wires to the bridge and checks that the input resistance of the bridge is reasonably close to what it should be.The disadvantages of this method are that it is more difficult and costly to implement, calibration constants become more difficult to deal with, and it can actually make troubleshooting the system more complicated.

C-6 Application NotesWhen a system is defined, the decision of what kind of electrical calibration to use should be set-tled during system definition prior to sale. As a rule of thumb:

• If the load can be removed routinely, such as a simple crane application, then choose shunt calibration.

• If the load cannot be removed easily, then choose voltage substitution.At this time, one should also start planning for a physical calibration at the commissioning of the system. This physical calibration must be performed at least once so that accurate cal constants can be acquired. These values become the calibration constants for future maintenance and routine cal-ibrations.

+EX

- EX

+Sig

-Sig

175KΩ

Strain

175KΩ

GaugeBridge

+EX

- EX

+Sig

-Sig

StrainGaugeBridge

1750KΩ

1750KΩ

350Ω 350Ω

High Cal Point Divider Low Cal Point Divider


Bulk Tank System APPENDIX CManual XC-130 Product Features

C-6-1 Routine Calibration

Provided you have calibration constants from a good physical calibration, frequent checks of system calibration can be accomplished by closing a switch and making sure the dis-played value matches the recorded value.

This means that in most applications, daily calibration checks can be performed by the operator. Maintenance personnel are not needed except to resolve situations where the dis-played value does NOT match the recorded value.

C-7 Product Features• 2077 Motherboard

q Shuntcal 1 - standard

q Shuntcal 2 - optional

q Voltage Substitution - optional, full scale configure per job

q Voltage Substitution - optional, shorted for zero

• SC103

q Shuntcal - optional, specified per job

• SC104

q Voltage Substitution (0.2 mV/V) for zero

q Voltage Substitution (0.4 mV/V) for 0.5 mV/V sensor



q Shuntcal or other values of Voltage Substitution available on special order

• Series 2000 Instruments

q Optional calibration relays for driving remote calibration circuits—shuntcal, voltage substitution, bridge substitution, or others

q Strain gauge input version has on-board shuntcal relays standard—shuntcal resistor(s) mounted on the terminal blocks on the rear of the unit

Dipswitch Selectable


APPENDIX C Bulk Tank SystemProduct Features Manual XC-130


C

APPENDIX DSTRAIN GAUGE LOAD CELL TROUBLESHOOTING

D-1 OverviewThis chapter provides technical information to assist field personnel in troubleshooting load cells. The first part of the chapter discusses background information about load cells. The last part of the chapter deals with the techniques used to troubleshoot load cells.

D-2 Excitation Voltage RequirementsSystems supplied by M/D TOTCO typically use a constant DC voltage supply. Typically, excita-tion voltages range from 5VDC to 15VDC. If the supplied voltage is higher than the strain gauge is designed to handle, it can damage the strain gauge. If the voltage is too low, the signal it yields will be so low that it will get lost in electrical noise. The following are examples of M/D TOTCO parts and the excitation voltages they supply:

The exact absolute value of the excitation voltage is typically not the primary concern. The pri-mary concern is the stability of the voltage level over time and changes in temperature. Exceptions to this are instruments which "ratiometrically" track change in excitation voltage over time or change in temperature. These instruments internally compensate for the drift in excitation voltage. M/D TOTCO (Metrox) instruments typically are configured for stable, absolute voltage supplies. The excitation voltage must also be as free of electrical noise as possible.

Excitation voltage must be measured at the load cell if possible. There will be a voltage drop in the interconnect cables between the signal conditioner and the load cell itself. In applications using long cable runs (>50') or requiring higher accuracy, remote sense techniques compensate for this voltage drop, which will be discussed later in this appendix.

CAUTIONThe following information is not meant to be a substitute for proper training.This information is provided as a guideline for technicians.

Part Excitation Voltage

2060 signal conditioner 6.9 VDC

2078 signal conditioner 6.9 VDC

CLM 200 signal conditioners 5.0 VDC

S-2000 instruments have user selectable excitation voltages 1.25 VDC, 2.5 VDC,5.0 VDC, and 10 VD

August 19, 1999 Page D-1M/D TOTCO

APPENDIX D Bulk Tank SystemLoad Cell Signal Manual XC-130

D-3 Load Cell SignalA strain gauge bridge supplies a very small electrical signal proportional to the force being mea-sured. The signal itself is a differential signal. This means that the value of the signal is the differ-ence between the voltage read off of opposite sides of the bridge, as shown in Figure D-1.

Figure D-1. Signal Detection Points

The value of +signal and -signal have meaning only in reference to each other. The signal is not measured with respect to ground.

The signal must be measured with equipment having high impedance inputs, otherwise current will be pulled through the signal wires causing errors. Most modern digital volt meters (DVM’s) have sufficiently high impedance inputs so as not to degrade the signal.

The value of the signal output from a strain gauge bridge is very low, typically 0–10 mV or 0–20 mV. Therefore, any volt meter used to measure these signals must have the capability to measure these low signal levels. For troubleshooting in the field, the minimum voltmeter requirement is typically a 4 ½ digit DVM.

The value of the signal is proportional to both the excitation voltage and the applied load. There-fore, the unit of measure for these signals is expressed in millivolts of signal per volt of excitation (mV/V). That is, for each volt of excitation supplied, you get some millivolt of signal. For exam-ple, if a load cell has an output of 2.0mV/V, and it has an excitation voltage of 10VDC applied to it, then the signal level should be 20mV (2mV for every volt of excitation; 2 x 10=20).

+Excitation

-Signal+Signal

differential signal measuredacross here

Voltage (+Ex)

-Excitation

StrainGauges

Voltage (-Ex)

Page D-2 August 19, 1999M/D TOTCO

Bulk Tank System APPENDIX DManual XC-130 Bridge Resistance

D-4 Bridge ResistanceGenerally, Metrox sensors from M/D TOTCO are configured in a Wheatstone bridge as shown in Figure D-1. Total bridge input resistance is measured from (+)Ex to (-)Ex. Bridge output resistance is measured from (+) Signal to (-) Signal.

Typical bridge output resistance values are 350 Ω or 700 Ω. Input resistance should be the same as the output resistance, however, there are systems where the input resistance is greater due to inter-nal compensation, which is usually less than 100 Ω. Refer to the specification control drawing for the nominal bridge resistance of a particular load cell.

D-5 Insulation ResistanceThe body of each load cell is electrically isolated from the bridge. To measure the insulation resis-tance of the load cell, the bridge must be disconnected from its instrumentation, and there must be NO power applied. Resistance can be measured from any or all bridge leads to the body of the load cell. This resistance must be greater than 100 MΩ Typically, values are greater than 5000 MΩ..

The average DVM applies less than 9 VDC, so it shouldn’t cause any damage. However, many of these DVM’s are often unable to measure as high as 100 ΜΩ.

D-6 Interconnect TechniquesAll full bridge load cells require a minimum of four interconnect wires:

Figure D-2. 4-Wire Configuration Diagram

NOTEWhen measuring bridge resistance, the bridge must be disconnected fromthe instrumentation and there must be absolutely NO electrical connectionto the bridge except the ohmmeter.

WARNING

DO NOT use a high-voltage Hypot tester! Test equipment must apply nomore than 50 VDC. If internal varisters are used for lightning protection, thetest equipment must apply no more than 20 VDC.

+EX

- EX

-Sig

+SigSignal Conditioner,Display,Recorder,Etc.


APPENDIX D Bulk Tank SystemTroubleshooting Techniques Manual XC-130

Interconnect cables need to be twisted, shielded pairs. The two excitation lines are one twisted pair, and the signal lines are a second twisted pair. Shields are normally connected to ground only at the instrumentation end and not at the sensor end.

If even a small amount of current flows through the excitation wires, it creates a voltage drop. This drop means that the excitation voltage at the load cell is less than the excitation voltage at the instrument, which causes errors in the measurements being taken. To overcome this, you can run an additional twisted pair of wires from the load cell to the instrument, so the instrument can remotely sense the voltage at the load cell. The instrument can then compensate for the voltage drop in the excitation wires. Remote sense is recommended for all applications with long cable runs, or for applications that require a high degree of accuracy. Cable runs of less than 50 feet that don’t require high accuracy typically do not need remote sense.

Figure D-3. 6- or 7-Wire Configuration Diagram

When remote sense and shunt calibration are included together in the same application, a seventh wire is usually added to provide a current carrying path that is separate from the -Signal wire. This information is used by the instrument to overcome error induced by the current flow. Refer to Appendix C for more information on shuntcal.

D-7 Troubleshooting TechniquesThe following are functional tests for strain gauge load cells. The tests described below should be performed before requesting field support. Use the blank page at the end of this appendix to record the results so they will be easily accessible when working with field support.

D-7-1 Insulation Resistance

1. Disconnect the load cell from the interconnect cable if attached by a connec-tor or terminal block.

2. Measure the resistance from any or all leads to the body of the load cell.

3. If the resistance is less than 100 MΩ, the load cell is faulty.

WARNING

DO NOT use a Hypot tester! Test equipment must apply no more than50 VDC. If internal varisters are used for lightening protection, the testequipment must apply no more than 20 VDC.

+EX

- EX

-Sig

+Sig

Signal Conditioner,Display,Recorder,Etc.

+Remote Sense

-Remote Sense

Shunt Cal

Shunt Cal


Bulk Tank System APPENDIX DManual XC-130 Troubleshooting Techniques

D-7-2 Cable Insulation Resistance

(Does Not Apply To Integral Cables)

1. Disconnect the interconnect cable from both the load cell and the instrument.

2. Verify that the insulation between each wire is good by measuring the resis-tance between each wire, making sure it meets spec.

3. Verify that the insulation between each wire and the shield is to spec.

D-7-3 Bridge Resistance

1. Disconnect the load cell from the interconnect cable.

2. Measure the bridge resistance and verify it is to spec.

3. Reconnect the interconnect cable to the load cell, and disconnect the cable from the instrument.

4. Measure the bridge resistance through the cable. It should be within a few ohms of the bridge resistance measured at the load cell.

D-7-4 Excitation Voltage

1. Disconnect the load cell from the interconnect cable.

2. Connect the instrument to the interconnect cable, and power the instrument.

3. Verify that the excitation voltage at the load cell end of the cable is to spec.

D-7-5 Signal Voltage

1. Connect load cell to instrument.

2. Verify that the voltage between (-) excitation and (-) signal is ½ of the excita-tion voltage.

3. Verify that the voltage between (-) excitation and (+) signal is ½ of the excita-tion voltage.

4. Using a digital volt meter that can measure small voltages, verify that the volt-age between (+) signal and (-) signal is less than 2mV when there is no load applied to the load cell.

5. Apply some load to the load cell and verify that the signal voltage increases with the right polarity.

6. Activate the shunt calibration and/or the voltage substitution circuits and ver-ify their operation.

NOTEMeasuring the bridge resistance through the interconnect cable onlyverifies that the cable makes connection. There can still be wiring errors,such as swapped polarities on the signal or excitation wires. Therefore, inall new installations, a pin-to-pin verification must be performed.


APPENDIX D Bulk Tank SystemTroubleshooting Techniques Manual XC-130

Troubleshooting Field Notesfrom Section D-7-1

Insulation resistance ________________Ω

from Section D-7-2

Lowest cable insulation resistance_______________Ω

from Section D-7-3

Bridge resistance at load cell input_______________Ω ouput_____________Ω

Bridge resistance through cable input_______________Ω ouput_____________Ω

from Section D-7-4

Excitation Voltage (Vex) _______________V

from Section D-7-5

+Signalex _______________V

-Signalex _______________V

Signal ______________mV


APPENDIX EOPTION MODULES

E-1 OverviewSeries 2000 instruments can accept up to four plug-in option modules, which are used for interfac-ing with external equipment. Examples include serial communications, analog output, etc.

Located on the back of Series 2000 instruments, under the break-away tabs labeled OPT1, OPT 2, OPT 3, and OPT 4, are four 28-pin sockets for option modules.

Figure E-1. Series 2000 Back Cover

Electrically, all sockets are identical with the exception of pin 1, which is an “address” or “select” line. As a result, some module types work the same in all four sockets, and some have different functions depending on which position they are installed. The model code reflects which module is installed in which socket at the factory. Option modules may also be field installed.

E-2 Analog Output ModuleThere are two different types of analog output modules:

NON-ISOLATED—provide a sourced 4–20mA signal as well as a +/- 10VDC output signal. Sig-nals are referenced to the + 24VDC power supplied by the Series 2000 instrument.

ISOLATED—provide a ground isolated 4–20mA signal. This signal appears to external equip-ment like a 2-wire transmitter. A 24VDC power supply is available via the terminal block for con-venience, but it is NOT isolated.

2

August 19, 1999 Page E-1M/D TOTCO

APPENDIX E Bulk Tank SystemAux Comm Module Manual XC-130

Although any analog output module will work in any socket, each socket is assigned a particular parameter. For example, on an LM2000, socket #1 is assigned to tension, #2 is payout, and #3 is speed (#4 not applicable). Likewise, on a CI2000, socket #1 is main fall gross load, #2 is whip fall gross load, #3 is boom angle, and #4 is aux fall if applicable. Any or all applicable analog output modules can be installed at one time. You can freely mix isolated and non-isolated analog mod-ules.

E-3 Aux Comm ModuleThe purpose of the aux comm output is to provide the real-time value of the measured parameters to external customer equipment, such as computers, data loggers, etc. Aux comm also allows some operator commands to be transmitted from the external device into the instrument. These com-mands include acknowledging alarms, activating calibration relays for cal verification, performing or reporting self-tests, and resetting certain values to zero. Aux comm cannot be used for calibra-tion or configuration.

There are two different analog output modules used for aux comm:

• RS232• RS485

Instrument software responds the same regardless of which module is installed; the system acts like a half duplex party line (even with RS232). For a detailed description of the aux comm proto-col, refer to Appendix F.

Aux comm modules may be installed in any of the option module sockets, but typically they are installed in the OPT 4 socket.

E-4 Event Input ModuleThe purpose of the event input module is to allow you to connect external switches to Series 2000 instruments. This module can be installed in any of the option module sockets. Event input mod-ules can accommodate two switches. Typically, this option is used for external reset (value to zero) and push to print (transmits present value out through aux comm).

NOTEOnly one aux comm module can be installed per instrument at any one time.

NOTEOnly one event input module can be installed per instrument at any one time.

Page E-2 August 19, 1999M/D TOTCO

Bulk Tank System APPENDIX EManual XC-130 Installation

E-5 Installation1. Locate the four rectangular tabs on the back of the instrument labeled OPT 1, OPT 2,

OPT 3, and OPT 4.

Figure E-2. Series 2000 Back Cover (Option Module Socket Covers Highlighted)

2. Remove the rear cover by loosening the six, black retaining screws securing the cover to the unit.

3. Break out the appropriate tabs to expose the required option module sockets.

4. Verify that all of the pins on the bottom of the option module are straight. If neces-sary, carefully bend them back straight. All pins must be straight for the module to fit in the instrument.

5. Using the four long guide pins, carefully position the module over the socket.

August 19, 1999 Page E-3M/D TOTCO

APPENDIX E Bulk Tank SystemInstallation Manual XC-130

6. Place your fingers on the terminal block and the edges of the housing and press firmly until the module is fully seated in the socket. DO NOT apply excessive force to the center of the housing. Refer to Figure E-3.

Figure E-3. How to Properly Seat an Option Module

7. Tighten the two captive screws.

For general information on option module interconnect wiring, refer to Chapter 2.

For more specific examples of option module interconnect wiring, refer to Appendix H.

For specific information on option module interconnect wiring on turn-key systems, refer to the interconnect drawings supplied with the system.

Press here

Press here

Page E-4 August 19, 1999M/D TOTCO

APPENDIX FAUXILIARY COMMUNICATIONS (AUX COMM)

F-1 OverviewThe purpose of auxiliary communication output is to provide real-time values of measured param-eters to external equipment, such as computers, data loggers, etc. Some operator commands can also be transmitted from an external device into a Series 2000 instrument. Examples of these are ACKnowlege alarms, activate CAL1 or CAL 2 relays, perform or report SELFTEST, and RESET certain values to zero.

There are two types of aux comm modules that can be installed in one of the option module slots on the back of Series 2000 instruments:

• RS232• RS485

Although an aux comm module can be installed in any of the option module slots, typically it is installed in slot 4.

F-2 Protocol SelectionThere are three different protocols to choose from for aux comm:

PROTOCOL #1—the original, simplified comm protocol which is limited to the three basic com-mands (SS, CS, and CD). This protocol is still a good choice when connecting only one Series 2000 instrument to a computer. This protocol also allows for support of older, existing field instal-lations.

PROTOCOL #2—features of protocol #1 plus an expanded instruction set and more efficient pro-tocol for party line applications.

Continuous Mode—forces the instrument to automatically power up in the continuous scan mode. The instrument acts like it has received a CS command. This is typically used when the instrument is connected to a serial printer. The transmission interval is programmable via the front panel, from 0.25 sec to 60 sec (in 0.25 sec increments).

F-3 Command ListSS (single scan)—request for a single transmission of all present values.

CS (continuous scan)—same as SS, only the transmissions will continue at a programmed interval until an "ESCape" character is received or the instrument is reset.

CD (configuration dump)—request for a list of all configuration information. The answer returned includes calibration constants, a channel list for the product (this list matches the channels trans-mitted for SS and CS), alarm limits, and device numbers.

NOTEOnly one aux comm module can be installed in a Series 2000 instrument at one time.

August 19, 1999 Page F-1M/D TOTCO

APPENDIX F Bulk Tank SystemDelimiter Selection Manual XC-130

ACK (acknowledge)—acknowledges alarms the same as pressing the front panel ACK button. This silences all horns (internal and external), but does NOT clear the general purpose relays. There is no response transmitted back from the instrument.

C1 (CAL 1)—turns on the "CAL 1" relay on the back of the instrument the same as activating the relay from the front panel. The relay is cleared by transmitting an "ESCape" character to the instrument. There is no response transmitted back from the instrument for either the C1 or the "ESCape" signal.

C2 (CAL 2)—turns on the "CAL 2" relay on the back of the instrument the same as activating the relay from the front panel. The relay is cleared by transmitting an "ESCape" character to the instrument. There is no response transmitted back from the instrument for either the C2 or the "ESCape" signal.

RS (reset)—resets the present value to zero. In the case of an LM2000, it resets the payout to zero. In the case of the CI2000, the main net load and whip net load are set to zero (new "TARE" value). There is no response transmitted back from the instrument.

ST (perform self test)—causes the instrument to perform the power up self test sequence. The instrument is forced to reset and automatically runs the power-on self tests. There is no response transmitted back from the instrument.

RT (report self test)—requests a transmission of the self test results that were stored at the last self test. This does not trigger the instrument to perform a self test.

F-4 Delimiter SelectionIn the SS and CS commands, the values returned are separated by a programmable character. The choices are:

• Comma• Space• Tab

NOTEThe ST command causes a disruption in operation of the unit.

Page F-2 August 19, 1999M/D TOTCO

Bulk Tank System

APPEN

DIX F

Manual XC

-130 PR

OTO

CO

L #1

August 19, 1999

Page F-3M

/D TO

TCO

F-

)

lts as follow:

5 PROTOCOL #1The basics of protocol #1 involve:—signing on to particular unit—receiving a response of self-test results from the unit—sending one of three commands (SS, CS, or CD)—receiving the response back from the instrument until you log onto another unit.

Once the communications wiring is properly connected, aux comm is initiated as follows:

1. Sign on to a particular Series 2000 unit by sending the following command:

where !! = sync charactersnn = device address number (drop address)

for sensor input units, the drop address = rotary switch setting (01–16for remote displays, the drop address = remote # + 16 (17–31)for single device systems, the drop address is usually = 01

2. As a response to the "!!nn" command, the Series 2000 instrument will answer back with self test resu

whereA = one digit result of sensor unit CPU ram test

0 if passed1 if failed

B = one digit result of sensor unit CPU PROM test0 if passed1 if failed

C = one digit result of sensor unit CPU EEPROM test0 if passed1 if failed

DDD = three digit error count for -15V power supply

! ! n n

cr lfA B C D D D E E E F F F G G G H H H J J J cr lfK L M N cr lf

APPEN

DIX F

Bulk Tank System

PRO

TOC

OL #1

Manual XC

-130

Page F-4A

ugust 19, 1999M

/D TO

TCO

000 if no errors001–999 if any errors

EEE = three digit error count for +15V power supply000 if no errors001–999 if any errors

FFF = three digit error count for +24V power supply000 if no errors001–999 if any errors

GGG = three digit error count for 3.84V reference000 if no errors001–999 if any errors

HHH = three digit error count for A/D calibration errors000 if no errors001–999 if any errors

JJJ = three digit error count for A/D data ready errors000 if no errors001–999 if any errors

K = one digit result of display CPU RAM test0 if passed1 if failed

L = one digit result of display CPU PROM test0 if passed1 if failed

M = one digit result of display CPU EEPROM test0 if passed1 if failed

N = one digit result of display CPU bank PROM test0 if passed1 if failed

Now that the unit is on-line and active, it will respond to the commands SS, CS or CD that make up Protocol #1.

Bulk Tank System

APPEN

DIX F

Manual XC

-130 PR

OTO

CO

L #1

August 19, 1999

Page F-5M

/D TO

TCO

F-5-1 SS Command

When you send the SS command to a Series 2000 instrument, you are asking it to respond with a Single Scan of current values and alarm status information.

To send the SS command from a terminal or computer, simply type "SS" at the keyboard. The instrument will respond with information in the following format:

wherenn = sensor unit number (drop address) of the sensor unit sending this dataFF...F = current value in floating point format, including sign and decimal,

right justified with decimal position depending on channel precision Current value and status information provided for as many channelsas listed in the response to the CD command, and in the same order.

S = one character alarm status responseH for high-high alarmh for high alarml for low alarmL for low-low alarmSpace (blank) if no alarm condition

cr = carriage returnlf = line feed

F-5-2 CS Command

When you send the CS command to a Series 2000 instrument, you are asking it to respond with a Continuous Scan of current values and alarm status information, at an interval you determine when configuring the instrument.

To send the CS command from a terminal or computer, type "CS" at the keyboard. The instru-ment will respond with information in the same format as a SS, only it will continue updating the information until you press the Esc key on the keyboard.

cr lfn n , F F F F F F F , S , F F F F F F F , S , F F F F F F F , S cr lf

APPEN

DIX F

Bulk Tank System

PRO

TOC

OL #1

Manual XC

-130

Page F-6A

ugust 19, 1999M

/D TO

TCO

c

I M I T L L - L I M I T cr lfC F F F F F F F F F F F cr lfC F F F F F F F F F F F cr lfC F F F F F F F F F F F cr lfc

CCc

H - S C A L E cr lfC N N N N cr lfC N N N N cr lfC N N N N cr lf

F-5-3 CD Command

When you send the CD command to a Series 2000 instrument, you are asking it to respond with a Configuration Dump of the currently selected instrument. The instrument will respond with data in the following format:

where: Device number = drop address as defined in the command formatSensor unit number = drop address of the sensor unit you’re viewing data fromCC...C = channel name, right justified with leading blanksUU...U = units name, right justified with leading blanksFF...F = current value in floating point format, including sign and decimal,

right justified with decimal position depending on channel precisionNN...N = integer format, right justified with leading blankscr = carriage returnlf = line feed

r lfD E V I C E # N N cr lfS E N S O R U N I T # n n cr lf

C H A N N E L U N I T S H H - L I M I T H - L I M I T L - LC C C C C C C C C C C C C U U U U U U F F F F F F F F F F F F F F F F FC C C C C C C C C C C C C U U U U U U F F F F F F F F F F F F F F F F FC C C C C C C C C C C C C U U U U U U F F F F F F F F F F F F F F F F F

r lfC A L I B R A T I O N D A T A cr lf

C H A N N E L O F F S E T S L O P E cr lfC C C C C C C C C C C C C F F F F F F F F F F F . F F F F cr lfC C C C C C C C C C C C C F F F F F F F F F F F . F F F F cr lf

r lfA N A L O G O U T P U T C A L I B R A T I O N D A T A cr lf

C H A N N E L O F F S E T S L O P E L - S C A L EC C C C C C C C C C C C C N N N N F F F F . F F F F F N N N NC C C C C C C C C C C C C N N N N F F F F . F F F F F N N N NC C C C C C C C C C C C C N N N N F F F F . F F F F F N N N N

Bulk Tank System

APPEN

DIX F

Manual XC

-130 Protocol #2

August 19, 1999

Page F-7M

/D TO

TCO

F-

.)

)

.

6 Protocol #2Protocol #2 is the preferred protocol for “party line” applications. In protocol #2, the sign on and the request for data are part of the same command, thereby not wasting transmission bandwidth on sending expanded self-test results over and over. Also note that a four character system status/self-test status is added to the SS and CS response. If these results show a self-test failure, then the more detailed self-test results can be requested. In addition, protocol #2 has a device address wild card. For commands that require NO response, the device address can be replaced with “$$”, which will cause all connected units to take the action the command specifies. Typical uses are activating cal relays (C1) or acknowledging alarms (AK).

Once the communications wiring is properly connected, aux comm protocol #2 is initiated as fol-lows:

Sign on to a particular Series 2000 unit by sending the following command:

where !! = sync charactersAA = two character command (first characters must be alpha, i.e. SS, CD, etcnn = device address number (drop address)

for sensor input units, the drop address = rotary switch setting (01–16for remote displays, the drop address = remote # + 16 (17–31)$$ if the command applies to all devices (drop addresses) and requiresno response from the devices


A list of valid commands and their expected response formats are described in the following sub sections

! ! A A n n cr

lf

APPEN

DIX F

Bulk Tank System

Protocol #2M

anual XC-130

Page F-8A

ugust 19, 1999M

/D TO

TCO

c

I M I T L L - L I M I T cr lfC F F F F F F F F F F F cr lfC F F F F F F F F F F F cr lfC F F F F F F F F F F F cr lfc

CCc

H - S C A L E cr lfC N N N N cr lfC N N N N cr lfC N N N N cr lf

F-6-1 CD Command

When you send the CD command to a Series 2000 instrument, you are asking it to respond with a Configuration Dump of the currently selected instrument. The instrument will respond with data in the following format:

where: Device number = drop address as defined in the command formatSensor unit number = drop address of the sensor unit you’re viewing data fromCC...C = channel name, right justified with leading blanksUU...U = units name, right justified with leading blanksFF...F = current value in floating point format, including sign and decimal,

right justified with decimal position depending on channel precisionNN...N = integer format, right justified with leading blankscr = carriage returnlf = line feed

r lfD E V I C E # N N cr lfS E N S O R U N I T # N N cr lf

C H A N N E L U N I T S H H - L I M I T H - L I M I T L - LC C C C C C C C C C C C C U U U U U U F F F F F F F F F F F F F F F F FC C C C C C C C C C C C C U U U U U U F F F F F F F F F F F F F F F F FC C C C C C C C C C C C C U U U U U U F F F F F F F F F F F F F F F F F

r lfC A L I B R A T I O N D A T A cr lf

C H A N N E L O F F S E T S L O P E cr lfC C C C C C C C C C C C C F F F F F F F F F F F . F F F F cr lfC C C C C C C C C C C C C F F F F F F F F F F F . F F F F cr lf

r lfA N A L O G O U T P U T C A L I B R A T I O N D A T A cr lf

C H A N N E L O F F S E T S L O P E L - S C A L EC C C C C C C C C C C C C N N N N F F F F . F F F F F N N N NC C C C C C C C C C C C C N N N N F F F F . F F F F F N N N NC C C C C C C C C C C C C N N N N F F F F . F F F F F N N N N

! ! C D n n cr lf

Bulk Tank System

APPEN

DIX F

Manual XC

-130 Protocol #2

August 19, 1999

Page F-9M

/D TO

TCO

F-6-2 SS Command

When you send the SS command to a Series 2000 instrument, you are asking it to respond with a Single Scan of current values and alarm status information.

To send the SS command, simply type at the keyboard. The instrument will respond with information in the following format:

wherenn = sensor unit number (drop address) of the sensor sending this dataFF...F = current value in floating point format, including sign and decimal,

right justified with decimal position depending on channel precision Current value and status information provided for as many channelsas listed in the response to the CD command, and in the same order.

S = one character alarm status responseH for high-high alarmh for high alarml for low alarmL for low-low alarmSpace (blank) if no alarm condition

XXXX = four character system statusCAL1 if the CAL1 relay is active, affecting current valuesCAL2 if the CAL2 relay is active, affecting current values0000 if no cal relay is active and all self tests passed0001–9999 if no cal relay is active and there are any self test failures


cr

lf

n n , F F F F F F F , S , F F F F F F F , S , F F F F F F F , S , X X X X cr

lf

! ! S S n n cr lf

! ! S S n n cr lf

APPEN

DIX F

Bulk Tank System

Protocol #2M

anual XC-130

Page F-10A

ugust 19, 1999M

/D TO

TCO

ro for applicable channels (i.e. PAY-

F-6-3 CS Command

When you send the CS command to a Series 2000 instrument, you are asking it to respond with a Continuous Scan of current values and alarm status information, at an interval you determine when configuring the instrument.

To send the CS command, type at the keyboard. The instrument will respond with information in the same format as an SS, only it will continue updating the infor-mation until you press the Esc key on the keyboard.

F-6-4 AK Command

This command acknowledges alarms.

Series 2000 instruments send no response back, but acknowledges all alarms.

F-6-5 C1 Command

Sending the C1 command turns on the CAL1 relay.

Sending an escape (Esc) character turns off the CAL1 relay.

F-6-6 C2 Command

Sending the C2 command turns on the CAL2 relay.

Sending an escape (Esc) character turns off the CAL2 relay.

F-6-7 RS Command

Sending the RS command resets a value to zero.

Series 2000 instruments send back no reply to this command, but do reset the current value to zeOUT, TARE, etc.).

F-6-8 ST Command

Sending the ST command causes the system to reset, which then causes a self test to occur.

Series 2000 instruments send back no reply to this command.

! ! C S n n cr lf

! ! C S n n cr lf

! ! A K n n cr lf

! ! C 1 n n cr lf

! ! C 2 n n cr lf

! ! R S n n cr lf

! ! S T n n cr lf

Bulk Tank System

APPEN

DIX F

Manual XC

-130 Protocol #2

August 19, 1999

Page F-11M

/D TO

TCO

F-6-9 RT Command

As a response to the "RT" command, the Series 2000 instrument will answer with self test results as follows:

whereA = one digit result of sensor unit CPU ram test

0 if passed1 if failed

B = one digit result of sensor unit CPU PROM test0 if passed1 if failed

C = one digit result of sensor unit CPU EEPROM test0 if passed1 if failed

DDD = three digit error count for -15V power supply000 if no errors001–999 if any errors

EEE = three digit error count for +15V power supply000 if no errors001–999 if any errors

FFF = three digit error count for +24V power supply000 if no errors001–999 if any errors

GGG = three digit error count for 3.84V reference000 if no errors001–999 if any errors

HHH = three digit error count for A/D calibration errors000 if no errors001–999 if any errors

cr lfA B C D D D E E E F F F G G G H H H J J J cr lfK L M N cr lf

! ! R T n n cr lf

APPEN

DIX F

Bulk Tank System

Protocol #2M

anual XC-130

Page F-12A

ugust 19, 1999M

/D TO

TCO

JJJ = three digit error count for A/D data ready errors000 if no errors001–999 if any errors

K = one digit result of display CPU RAM test0 if passed1 if failed

L = one digit result of display CPU PROM test0 if passed1 if failed

M = one digit result of display CPU EEPROM test0 if passed1 if failed

N = one digit result of display CPU bank PROM test0 if passed1 if failed

Bulk Tank System APPENDIX FManual XC-130 Aux Comm Response Times

F-7 Aux Comm Response TimesIn certain applications, response time of the instrument to aux comm commands can be an impor-tant issue. The following guidelines must be considered when writing software to communicate with Series 2000 instruments.

F-7-1 SS (single scan) Command

Command processing overhead is measured from the time the last character of the com-mand is received to the time the first character of the reply is transmitted. This averages around 60ms, but occasionally varies upward to as much as 400ms if other system events are waiting to be processed when the command is received.

Reply transmission time must be added to the command process time to arrive at the over-all time for receiving full response for the command. This time will depend on baud rate and the number of channels in the response. Below is an example of how this is calculated for 9600 baud, and may be used to determine transmission time for other baud rates.

Example:

At 10 bits per character, character transmission time is about 1ms (10/9600).

At 10 characters per channel, channel transmission time is 10ms.

Therefore, total response time (command process + transmission time) for 10 channels is:

Typical = 60 + 100 = 160msPractical maximum = 400 + 100 = 500ms

In addition, each transmission includes a header (device number) and a trailer(status, [cr], [lf], etc.) which adds approximately 10 more characters.

F-7-2 C1 (CAL1) Command

Process time for this command ranges from 3ms to about 400ms. This command does not require any response to the host. Also, the process time for this command is applicable to all other commands that do not require any response (C2, AK, RS). Because this type of command is transmitted infrequently, it is recommended to wait >500ms after transmit-ting before transmitting any additional command.

F-7-3 CD (Configuration Dump) command:

Complete response time (process + transmission time) for this command is to be in the range of 1.25–1.5 seconds for 7 channels.

F-7-4 Conclusions on Response Time

Based on the data above, the following timing criteria is recommended for host communi-cation software:

When polling devices with the SS command for their current values, send the next poll when the complete response has been received. In the event that no response is received for 600ms, depending on channel count and baud rate, a time-out should abort the current poll and the next poll may be issued. Regardless, if a time-out is used, collisions may occur if the instrument response overlaps the next poll and the two devices are trying to

August 19, 1999 Page F-13M/D TOTCO

APPENDIX F Bulk Tank SystemAux Comm Response Times Manual XC-130

transmit at the same time. This type of collision will cause a UART error. Therefore, the host software should discard the response if there are any UART errors, and either retry the same device until some maximum retry is reached, or move on the next device.

When issuing any command like C1, which does not require any response, the next com-mand should not go out until a no-response time-out occurs.

When requesting a configuration dump with the CD command, sufficient time should be allowed to receive the complete response. As this time depends on the total number of channels (16 max), and it is only required once on start up, it is recommended that a 5 sec-ond time-out be used with this command.

Page F-14 August 19, 1999M/D TOTCO

APPENDIX GNETWORKING

G-1 OverviewNetworking is used to operate a group of up to 16 Series 2000 units together for the purpose of having remote displays, multiple displays, etc. This communication port is standard on all Series 2000 instruments through the TB3 connections on the back of each unit.

There are two different types of stations in a network:

• Sensor input unit• Remote display unit

G-2 Sensor Input UnitSensor input units come in two forms: those with displays, and those without displays.

G-2-1 Sensor Input Unit With Display

Displays on these units can only show data for the sensors that are connected to the unit. The display, therefore, cannot act as a remote display for other sensors.

G-2-2 Sensor Input Unit Without Display (DAQ)

Often referred to as remote data acquisition units (or DAQ’s), these must have remote dis-plays connected to them in order to calibrate or configure the unit.

There can be a maximum of 16 sensor input units in a network, but the total number of instruments in a single network cannot exceed 16.

G-3 Remote DisplayRemote displays cannot read signals directly from sensors. Remote displays must get their infor-mation from the network. They can, however, drive relays and option modules. Every remote dis-play can be configured (via the front panel) to act as a display for any sensor input unit in the network. Remote displays have access to all calibration and configuration features just like a local display on a sensor input unit. There can be a maximum of 15 remote displays in a network.

August 19, 1999 Page G-1M/D TOTCO

APPENDIX G Bulk Tank SystemSensor Input Unit Setup Manual XC-130

G-4 Sensor Input Unit Setup1. Using a small flat head screwdriver, set the rotary address switch on each sensor input

unit to a unique number. Refer to Figure G-1. Typically, you will want to set them to sequential numbers starting with number one.

Figure G-1. Rotary Address Switch Location on Rear Panel of Instrument

2. Power up the unit, and verify that the unit is configured as a “sensor input unit” in the Network Setup screen. See Section 3-10-4 for more information.

3. For units with displays, look in the Network Setup screen to see what switch setting the unit has. Always use this number and ignore what is printed on the switch itself.

4. For remote data acquisition units (sensor input units without displays), you must read the numbers printed on the rotary switch body. The switch is printed with hexadecimal numbers, so refer to the following table to determine what hexadecimal number corre-sponds to what switch setting:

The setting of the rotary switch becomes the unit number when referenced by any remote displays. For example, on LM2000 systems, this rotary switch sets the WINCH#. On CI2000 systems, this rotary switch sets the CRANE#.

G-5 Remote Display Unit Setup1. In the Network Setup screen, set all remote displays to a unique number,

i.e. "Remote Display #1" or "Remote Display #2"…"Remote Display #15".

2. Select a sensor unit number whose data is to be shown on the remote display by pressing the button labeled SCREEN in the main operators screen.

3. Highlight "Select ______" (winch, crane, etc.) and press the select key.

character printed on switch 0 1 2 3 4 5 6 7 8 9 A B C D E F

switch setting 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Rotary Address Switch

Page G-2 August 19, 1999M/D TOTCO

Bulk Tank System APPENDIX GManual XC-130 Network Examples

4. Select the number of the sensor unit you chose in step 2 above.

G-6 Network ExamplesThe following examples are diagrams of various network examples. The switch settings and net-work setup parameters are shown in each example.

G-6-1 Network #1—Remote DAQ to Remote Display

This example has one remote data acquisition unit connected to one remote display. This is the most basic kind of network.

Figure G-2. Remote DAQ to Remote Display

NOTEIf the data is ever corrupted, the remote display will have to load all newdefault values. The rotary switch setting of the remote display will be usedas the default unit number for that unit. Therefore, it is suggested that theswitch setting of the remote display match that of the sensor unit to bedisplayed remotely.

NOTEPlease note that the switch setting listed in the diagram refers to the switchsetting as displayed in the network setup screen, not what is printed on theswitch body itself. For more information on switch settings, refer toSection G-4

Sensor Input UnitSW=1

Remote Display #1SW=1

Sensors


APPENDIX G Bulk Tank SystemNetwork Examples Manual XC-130

G-6-2 Network #2—Sensor/Display to Remote Display

This example has one sensor/display unit connected to one remote display. This is the same as Network #1, but the sensor unit has its own display.

Figure G-3. Sensor/Display to Remote Display

G-6-3 Network #3—DAQ to Multiple Remote Displays

This example has one remote data acquisition unit connected to multiple remote displays. Any remote display can be used to calibrate/configure the remote data acquisition unit.

Figure G-4. DAQ to Multiple Remote Displays



Sensors



Sensors






G-6-4 Network #4—Sensor/Display to Multiple Remote Displays

This example has one remote display connected to a sensor/display unit. This is the same as Network #3, but the sensor unit has its own display.

Figure G-5. Sensor/Display to Multiple Remote Displays



Sensors






G-6-5 Network #5—Remote Display to Multiple DAQs

This example has one remote display connected to several remote data acquisition units, each hooked to separate sensors. The remote display can be used to calibrate/configure any one remote data acquisition unit at a time; the particular remote daq unit is selected via the remote display’s front panel “screen” button.

Figure G-6. Remote Display to Multiple DAQs


Remote Display #1

Sensors


SensorsSensor Input Unit

SW=2Sensors


Sensors



G-6-6 Network #6—Remote Display to Multiple Sensor/Displays

This example has one remote display unit connected to multiple sensor/display units. This is the same as Network #5, except each sensor has its own local display.

Figure G-7. Remote Display to Multiple Sensor/Displays


Remote Display #1

Sensors


SensorsSensor Input Unit

SW=2Sensors


Sensors



G-6-7 Network #7—Multiple Remote DAQs to Multiple Remote Displays

This example has several remote data acquisition units connected to several remote dis-plays, each display showing data from a different, single DAQ unit.

Figure G-8. Multiple Remote DAQs to Multiple Remote Displays



Sensors


Sensors


Sensors


Sensors






G-6-8 Network #8—Multiple Sensor/Display Units to Multiple Remote Displays

This example has multiple remote displays connected to multiple sensor/display units. The is the same as Network #7, except each sensor unit has its own local display. Any remote display can be used to calibrate/configure any one sensor/display unit. To choose which sensor unit a remote display will show, you must use the “screen” button on the remote display.

Figure G-9. Multiple Sensor/Display Units to Multiple Remote Displays



Sensors


Sensors


Sensors


Sensors





APPENDIX G Bulk Tank SystemNetworking and Aux Comm Manual XC-130

G-7 Networking and Aux CommStandard networking is carried out through the RS-485 interface provided by TB3 on the back of all Series 2000 instruments. The data is in a proprietary binary form, making it difficult to use out-side the network. In addition to the standard networking communications, it is possible to have auxiliary communications through an aux comm option module installed on the back of the unit.

Aux comm modules use standard ASCII data that is easier to work with on any terminal or PC, allowing the user to create programs that speak the “language” of aux comm. Both of these net-work communications can be used simultaneously. For more information on aux comm modules, see Appendix F

G-8 Network/Aux Comm ExamplesThe following examples are diagrams of various network/aux comm examples. The switch set-tings and network setup parameters are shown in each example.

NOTEPlease note that the switch setting listed in the diagram refers to the switchsetting as displayed in the network setup screen, not what is printed on theswitch body itself. For more information on switch settings, refer toTable G-4


Bulk Tank System APPENDIX GManual XC-130 Network/Aux Comm Examples

G-8-1 Network #9—Multi. Sensor/Display to Multi. Remote Displays w/ Aux Comm

This example has multiple sensor/display units connected to multiple remote displays with all remote displays connected to a PC. The host PC addresses the remote displays as numbers 17–32, where remote display #1 is address 17, remote display #2 is address 18, remote display #3 is address 19, etc.

Figure G-10. Multiple Sensor/Display to Multiple Remote Displays w/ Aux Comm



Sensors


Sensors


Sensors


Sensors




AUX

AUX

AUX

AUX

AUX unit #17 AUX unit #18 AUX unit #19 AUX unit #20

Host PC


APPENDIX G Bulk Tank SystemNetwork/Aux Comm Examples Manual XC-130

G-8-2 Network #10—Multi. Sensor/Display w/ Aux Comm to Multi. Remote Displays

This example has multiple sensor/display units connected to multiple remote displays, with all sensor/display units connected to a PC via aux comm. The host PC addresses the sensor/display units by their rotary switch settings, where the unit with a switch setting of 1 is addressed as 01, unit with switch setting 2 is addressed as 02, and so on.

Figure G-11. Multiple Sensor/Displays w/ Aux Comm to Multiple Remote Displays



Sensors


Sensors


Sensors


Sensors




AUX

AUX

AUX

AUX

Host PC

AUX unit #02 AUX unit #01

AUX unit #03 AUX unit #04


APPENDIX HINTERCONNECT EXAMPLE DRAWINGS

H-1 OverviewThe following drawings show wiring examples for various types of enclosures and equipment set-ups. Use these drawings as a reference when wiring Series 2000 systems.

Sheet 1 (221117-001)—SC103 with shuntcal connected to a load cell and an SP102 payout sensor.

Sheet 2 (221117-002)—2078 signal conditioner (and 2077 motherboard) with voltage substitution connected to an SP102 payout sensor.

Sheet 3 (221117-003)—2078 signal conditioner (and 2077 motherboard) with shuntcal connected to an SP102 payout sensor.

Sheet 4 (221117-004)—SC103 and prox sensors in a hazardous environ-ment, and the display in a safe area.

Sheet 5 (221117-005)—SC103 without shuntcal connected to a load cell and an SP102 sensor.

Sheet 6 (E6481-020 sht. 5)—PI 2000 Block Diagram for the Shpere supply system.

Sheet 7 (E6481-020 sht. 6)—PI 2000 Block Diagram for the Shpere supply system.

August 19, 1999 Page H-13M/D TOTCO

APPENDIX H Bulk Tank SystemOverview Manual XC-130

Page H-14 August 19, 1999M/D TOTCO

APPENDIX IILLUSTRATED PARTS LISTS

I-1 OverviewThe appendix contains a recommended spare parts list for the mud and cement console assemblies plus the surge and bulk tank assemblies.

Table I-1. Recommended Spare Parts List

PartNumber Description

Used In E6481-

QtyRq’d

943413-083 POWER SUPPLY, 24VDC, 6.2 A 100 2

932504-021 OPERATOR, SWITCH, LEVER 100, 200 28

932504-018 CONTACT BLOCK, 2 POLE, NRM. OPEN 100, 200 28

E5624-132 PUSH BUTTON, FLASH HD, BLK 100, 200 1

935422-001 LCD MODULE, 240 X 128 100, 200, 300 1

999328-028 SPACER, #6 X .50, .25 RND 100, 200, 300 6

220840-E6481-12 MAIN DISPLAY, REMOTE DISPLAY 100, 200, 300 1

220840-E6481-34 MAINDISPLAY, REMOTE DISPLAY 100, 200, 300 1

923302-020 LED, 5mm, RED, 10 mA 100, 200, 300 77

923302-021 LED, 5mm, GRN, 10 mA 100, 200, 300 77

221630 PCB ASSY, MIMIC INTERFACE 100, 200, 300 10

938228-017 FUSE, 5 AMP SLO-BLO 300 1

932312-067 PUSH BUTTON, DIV 2, NEMA 4/4X 300 1

932312-068 SWITCH, 3 POS, DIV 2, NEMA 4/4X 300 13

4400-00080 SURGE TANK DISPLAY, MAIN DISPLAY 100, 400 1

999202-120 STANDOFF, F/F, 6-32 X .75 100, 200, 300, 400

6

220837-001 PCBA, FIELD WIRING, STRAIN GAGE 100, 200, 300, 400

1

220854-002 COVER, SERIES 2000, STRAIN GAGE 100, 200, 300, 400

1

999314-100 WASHER, LOCK, INT, #6, SST 100, 200, 300, 400

6

2850-06080 SCREW, 6-32 X .50 PNHD, S 100, 200, 300, 400

6

August 19, 1999 Page I-1M/D TOTCO

APPENDIX I Bulk Tank SystemOverview Manual XC-130

999449-569 SCREW, 6-32 X .38, PNH, PHL 100, 200, 300, 400

2

999269-002 WASHER, LOCK, EXT, #6, SST 100, 200, 300, 400

2

220840-E6481-SURGE SURGE TANK DISPLAYS 400 1

TL101-5K-E6481-01 TENSION LINK ASSY, 10K 400 2

CC101-100K-6481-01 COMP L/C ASSY, 100K, 2mV, NRML 1000 16

Table I-1. Recommended Spare Parts List

PartNumber Description

Used In E6481-

QtyRq’d

Page I-2 August 19, 1999M/D TOTCO

Date post:	14-Apr-2016
Category:	Documents
Upload:	juan-jose-vesga-rueda
View:	4 times
Download:	0 times

XC-130

Documents