Alpha Moisture Systems DS5000 User manual

Document No:1188
Issue 2
Date 14/11/03
Model DS5000 Dewpoint Monitor
Instruction Manual
Alpha Moisture Systems
Alpha House
96 City Road
Bradford
BD8 8ES
England
Tel: [phone]
Fax: [phone]
Email: [email protected]
Web: WWW.amsytems.co.uk

1188 Instruction Man DS5000.doc Page ii
Instruction Manual
for the
DS5000 Dewpoint Monitor

1188 Instruction Man DS5000.doc Page iii
Index
1General Information ....................................................................................................1
2Safety Information .......................................................................................................1
2.1 Warning .................................................................................................................................1
2.2 Isolation .................................................................................................................................1
3Installation ....................................................................................................................2
3.1 Installing the Instrument into a Panel ....................................................................................2
3.2 Instrument Wiring..................................................................................................................2
3.3 Power Supply Cable...............................................................................................................3
3.4 Alarm and Output Cable Connectors: -..................................................................................3
3.5 Sensor Cable ..........................................................................................................................3
4Installing the Air/Gas Sampling System ....................................................................3
4.1 Piping installation Schematic.................................................................................................4
4.2 Piping Schematic Component Index......................................................................................5
5Installing and Commissioning the DT45 Sensor .......................................................5
6Default Instrument Configuration..............................................................................6
7Resetting the DS5000 ...................................................................................................6
8Programming the DS5000 ...........................................................................................7
8.1 Principle of Entering Numerical Data....................................................................................7
9Configuring the DS5000 ..............................................................................................7
9.1 unit .........................................................................................................................................7
9.2 AL 1 & 2................................................................................................................................8
9.3 bELL......................................................................................................................................8
9.4 PrES .......................................................................................................................................8
9.5 4-20 ........................................................................................................................................9
9.6 VoLt.......................................................................................................................................9
9.7 ACAL...................................................................................................................................10
9.8 oFSt......................................................................................................................................10
9.9 CodE ....................................................................................................................................11
9.10 InFo......................................................................................................................................11
9.10.1InFo-rmation Details.............................................................................................................12
10 Normal Operation of the DS5000 .............................................................................12
11 Pressure Correction ...................................................................................................13
11.1 Examples..............................................................................................................................13
12 Monitoring the System...............................................................................................13
13 Faults/Errors...............................................................................................................14
13.1 Other Error mesages ............................................................................................................14
14 DS5000 Specification..................................................................................................15
15 Appendix A – Software Menu Map..........................................................................16

1188 Instruction Man DS5000.doc Page 1 of 16
1General Information
•The DS5000 Monitor is a DIN style panel mounted moisture monitoring device
designed to work in conjunction with the DT45 Dewpoint Transmitters.
•The readout of moisture content is displayed on a backlit, 4 digits, seven segment
LCD, in any one of six selectable engineering units (see DS5000 specification). The
selected unit is displayed on a separate seven segment LED.
•The user has the option of displaying pressure corrected or uncorrected moisture
values.
•The instrument can be operated from either an AC or DC power source (see DS5000
specification for details).
•The DS5000 operation is controlled by a four-button membrane keypad. The user-
friendly software uses a simple menu selection process and incorporates several hot
keys to read the transmitter temperature and the two alarm trigger points.
•Two fully customer controllable access security levels.
•The Model DS5000 utilises the advanced DT45 Dewpoint Transmitter, which allows
complete interchange ability of transmitters.
•The calibration data is stored within the transmitter and is readable from the DS5000
display.
•The DS5000 can perform auto-calibration and implement offsets on the attached
transmitter. All the values are stored on the transmitter retaining the interchangeability
of the transmitters.
•The DS5000 has two full range alarms that can be set as rising or falling edge
triggered. These alarms are visual (LED), audible and activate changeover relays for
remote indication or control.
•The DS5000 also has two independently, variable span, fully controllable linear
outputs. 1) 4-20mA and 2) 0 to 5V. The voltage output can be factory set to 0-100mV
or 0-1V.
•Details of normal operation, engineering unit selection, transmitter data and
configuration of the instrument are described within this manual.
2Safety Information
Read the safety information below, before installation.
2.1 Warning
Hazardous voltages may be present on instrument terminals. The equipment must be installed
by suitably qualified personnel and the instrument must be mounted in a position that
provides protection, behind the panel, to at least IP20.
2.2 Isolation
The power supply terminals and associated internal circuitry are isolated from all other parts
of the equipment in accordance with EN61010-1 for connection to a category II supply
(pollution degree2).

1188 Instruction Man DS5000.doc Page 2 of 16
Any terminals or wiring connected to the input or output, which are accessible in normal
operation, must only be connected to signals complying with the requirements for Safety
Extra Low voltage (SELV) circuits.
The mains supply to the instrument must be protected by an external 1-amp fuse and a
suitable switch or circuit breaker, which should be near the instrument.
Note: The instrument contains no user serviceable parts.
3Installation
3.1 Installing the Instrument into a Panel
Make a cut-out in the donor panel 138.0 x 68.0mm (DIN 43700).
The maximum panel thickness is 8mm and, if an effective IP65 weatherproof seal is required,
the minimum recommended panel thickness is 1.6mm.
Pass the instrument case through the cut-out in the donor panel and attach the two retaining
screws to the studs on either side of the case.
Tighten the retaining screws onto the back of the donor panel until the instrument is clamped
securely in position. The screws must be tightened sufficiently to affect a seal between the
front of the donor panel and the back of the instrument bezel, but never over tightened.
3.2 Instrument Wiring
Wire the DS5000 as per figure 1.1 below.
Figure 1.1
SENSOR
CONNECTIONS
A B C D + -+ -NO C NC NO C NC + -N GND L
RED
BLUE
GREEN
YELLOW
+ve
GN
D
-ve
Power Supply
90-250V AC
50/60 Hz
Max Power
10VA
-ve
+ve
Power Supply
12V DC
Max Power
10VA
Alarm 2
Alarm 1
NC
NC
N
O
N
O
+
-
4-20mA
Output
+
-
0-5V
Output

1188 Instruction Man DS5000.doc Page 3 of 16
3.3 Power Supply Cable
The DS5000 can be powered by either a 90-250V AC or 12V DC supply. Connect the
required supply cable to the appropriate terminals as shown in figure 1.1.
The AC power supply should be between 90 and 250V AC @ 50/60Hz.
The power supply wires are retained by screws. Ensure that the exposed section of the wire is
fully inserted and that no loose strands are exposed.
3.4 Alarm and Output Cable Connectors: -
Connect the required cables to the appropriate terminals as shown in figure 1.1, noting the
normally open and normally closed relay contact positions, and that the correct polarity and
the maximum load specification are strictly observed for the analogue outputs.
Ensure that the wire is fully inserted and that no loose strands are exposed.
3.5 Sensor Cable
Connect the sensor cable as shown in figure 1.1. Ensure that the correct colour coding is
observed and that the cage is securely clamped onto the bootlace ferrules on the cable
provided.
Root the sensor cable to the intended site of the sensor.
4Installing the Air/Gas Sampling System
The piping installation schematic diagram (see section 4.1) shows all components, which
could be used in a dry gas measurement application although not all the items shown will be
required for every installation.
Care should be taken to ensure that the sample presented to the measuring sensor is not
contaminated with any component that will damage, contaminate or affect the sensor in a
way that will impair the system accuracy.
It is strongly recommended that the sample should not contain particulate matter, oil or other
heavy hydrocarbon condensate. If these components contaminate the sample system and/or
the measuring sensor, the system response time will be lengthened, although the sensor
calibration will not be effected.
The sample must not contain Ammonia, Chlorine, Ozone or any wet acid vapours or
liquid as these will permanently damage the sensor and impair calibration accuracy.
The flow rate, although not critical to the sensor measurement, should be low enough to
avoid abrasion to the sensor surface without being so low as to extend the system response
time to an unacceptable level. In general, a flow rate of between 2 and 3 litres/min at NTP
will give the right balance.

1188 Instruction Man DS5000.doc Page 4 of 16
The sensor is a variable capacitor, which is directly affected by changes in partial pressure of
water vapour, and these changes, that are proportional to the dew/frost point temperature, are
displayed on the instrument indicator.
The measuring sensor can be installed directly into the process line but this does create
problems with access for maintenance and calibration. It is for these reasons that we
recommend that the sensor be installed in a bypass, fast loop or total loss sample system
where the sensor is accessible without interrupting the main process flow line.
4.1 Piping installation Schematic
1
2
3
4A
4B
5
6
7
8
9
10
11
P
Main
Process
Line
Notes
a. The sample point should be on the upper surface of the horizontal pipe, or from a
vertical section of pipe, wherever possible.
b. The sample tube should run upwards from the sample point. If this is not possible,
then an inspection port or drain tap should be installed at the lowest point in the
sample system.

1188 Instruction Man DS5000.doc Page 5 of 16
4.2 Piping Schematic Component Index
1) Sample Isolation Valve -This is a recommended item as it allows access to the sample
system without interrupting the main process line.
2) Sample Tube –This should be stainless steel for dry air or gas applications but copper or
carbon steel can be used where wetter gases are to be measured. If any section of the
sample tube must be flexible then PTFE should be used. In most cases, 3mm OD (1/8”) is
sufficient as it provides good system response time within minimum flow. 6mm OD (1/4”)
tube can be used where pressure drops across the 3mm tube are too high
3) Filter Unit –A filter unit is recommended when the samples are likely to contain
particulate matter. If the air/gas sample contains heavy hydrocarbon condensate, the filter
must be of the coalescing type with a drain. The filter unit should be positioned as close to
the sample point as practical.
4) Pressure Reduction Valve or Pressure Regulator –If the sample is to be measured at
atmospheric pressure then the valve 4A should be fitted and 4B omitted from the system.
If the sample is to be measured, at full line pressure and the exhaust vented to atmosphere,
then valve 4B should be fitted and 4A omitted from the system. If measurements are to be
taken at full line pressure and the sample is to be returned to a part of the main line or a
vent, which is at a pressure higher than atmospheric, and the input to that line needs a
controlled pressure then both 4A and 4B will be required.
5) Sample Pressure Gauge –This is not a critical part of the moisture measurement but may
be required if Dew/Frost point measurements are to be made at higher than atmospheric
pressure.
6) Measuring Sensor.
7) Sensor Holder.
8) Desiccant Chamber –This item is required when the sampling is to be intermittent. When
installed it prevents the ingress of wet air to the sample system, while the sample is not
flowing, improving the response time.
9) Flow Control Valve –This can be a separate item or combined with the flow indicator.
10) Flow Indicator –The recommended sample flow is 2 to 3 SL/M.
11) Sample Exhaust –The exhaust can be vented to atmosphere or returned to the process line
as discussed above.
5Installing and Commissioning the DT45 Sensor
It is advisable to carry out an initial purge routine of the sample loop, before installing the
sensor, in order to remove the possibility of sensor damage on start-up.
Refer to the sample system schematic in section 4.1. Open the inlet isolation valve slowly,
until a small flow of air/gas at atmospheric pressure flows through the inlet pipe work to the
sensor holder and exhausts through the sensor entry port of the sensor holder.

1188 Instruction Man DS5000.doc Page 6 of 16
Allow this purge to continue for about 15 to 20 minutes to remove any residual moisture from
the sample pipe work and components.
Close the inlet isolation valve and install the sensor into the sensor holder. Locate and secure
the four pin sensor cable connector in positioned on the sensor. Use the locking screw in
order to affect a weatherproof seal.
NOTE
The Plug and socket will only locate in one position as the 0V pin is different to the
other three pins. However, the plug is designed so that when the retaining collar is
loosened the plug can rotate. Take care not to overly twist the wires within the DT45
case.
Open the inlet valve slowly, again and, by opening all valves after the sensor holder, allow a
low-pressure purge through the whole sample system. (Note. If a closed by-pass loop is
installed, this section of the procedure is not possible).
Set the required pressures and flows within the sample loop.
This completes the installation and commissioning but, on initial start-up, it could take
several hours for the system to reach equilibrium.
The instrument will now indicate the dewpoint of the air/gas surrounding the sensor, at sensor
pressure and the analogue outputs will be giving voltage and mA signals proportional to the
indicated dewpoint.
6Default Instrument Configuration
The standard factory settings are as follows
•The instrument will display the moisture content in oC Dewpoint.
•Both alarms are set to trigger when rising above 20oC.
•The internal buzzer is set to on.
•The pressure compensation value is set at 0Barg.
•The 4-20mA output is set to the full range of the transmitter e.g. 4mA = -80oC
20mA = 20oC
•The voltage output is set to the full range of the transmitter e.g. 0v = -80oC
5v = 20oC
•All ACAL calibrations are removed.
•All offsets are removed.
•All security codes are disabled.
7Resetting the DS5000
It is possible to reset the DS5000 to factory set conditions by powering up the unit while any
one of the four front panel keys is pressed. See ‘Default Instrument Configuration’ above for
details of the default values.

1188 Instruction Man DS5000.doc Page 7 of 16
8Programming the DS5000
8.1 Principle of Entering Numerical Data
Wherever a numerical number has to be entered into the DS5000 the following text will be
found. “Use the ‘S’, ‘T’, ‘12’, & ‘↵’ keys to enter ……”. The basic principle used to
enter numerical values (integer and floating point) is described here.
The first character of the LCD display flashes to indicate it is active. Use the ‘S’ and ‘T’
keys to select the required number between 0 and 9 (-1 and 9 in some engineering units) then
press the ‘12’ key to make the second character flash. Use the ‘S’ and ‘T’ keys to select
the required number between 0 and 9 then press the ‘12’ key to make the third character
flash. Continue this process until all four characters are entered. In the case of a floating-point
numbers, press the ‘12’ key again makes the decimal point (dp) active. Use the ‘S’ and
‘T’ keys to position the dp in the required position. A subsequent press of the ‘12’ key
makes the first character active again. Pressing the ‘↵’ key at any point confirms the
numerical value.
Note –The Passwords used within the DS5000 are made off four integers and does not use the dp.
Note –The only way to leave the numerical part of this routine without saving it is to allow the 60-
second timeout to occur.
9Configuring the DS5000
To activate the Systems Menu press the key sequence ‘↵’ ‘12’ ‘↵’. This will display the
‘SYS’ message on the LCD as portrayed in the System Menu Map (see Appendix A).
Pressing the ‘↵’ key again enters the system menu map at the ‘unit’ screen on the base level.
There are 11 base level options described below:
Note: The default set-up will go directly from the SYS message to the unit screen. However, if the user
has set a SYS password, then the user is prompted to enter the correct password before continuing on to
the base level.
Note: Most of the screens within the menu have an active 60-second timeout. Therefore, if no keys are
pressed within this period the unit reverts automatically to normal operation. In most cases where the
60-second timeout occurs, changes made are not implemented.
9.1 unit
Description - The unit menu option allows the user to select the required engineering units
(See DS5000 Specification section 14 for details). Once the engineering unit is selected the
DS5000 will only display and accept inputs in that chosen unit.
The current engineering unit is displayed in the seven segments LED during normal operation
Note: When the engineering unit is altered, the LCD display changes to show the current moisture level in the
selected unit.