futuredesion DR 5000 User manual

User's Manual
DR 5000
Circle Chart Recorder
UM-DR5000 Rev 2 9-2003
1

Warning Symbol
Use the Manual
This Symbol calls attention to an operating procedure, practice, or
the like, which, if not correctly performed or adhered to, could result
in personal injury or damage to or destruction of part or all of the
product and system. Do NOT proceed beyond a warning symbol
until the indicated conditions are fully understood and met.
Installers
System
Read Chapter 1, 2, 3
Read All Chapters
NOTE:
It is strongly recommended that a process should incorporate
a LIMIT like Future Design’s L91 which will shut down the
equipment at a preset process condition in order to preclude
possible damage to products or system.
Information in this user's manual is subject to change without
notice.
Copyright May 2003, Future Design Controls, all rights reserved.
No part of this publication may be reproduced, transmitted,
transcribed or stored in a retrieval system, or translated into any
language in any form by any means without the written permission
of Future Design Controls.
Future Design Controls
7524 West 98th Place
Bridgeview, IL 60455
Phone [phone]
Fax [phone]
E-mail [email protected]
www.futuredesigncontrols.com 2

Contents DR5000 Recorder
Page Number
3-1 Recorder Setup
3-2 Alarm Settings
Chapter 1 Overview
Chapter 2 Installation
Chapter 3 Programming
Chapter 4 Calibration
Chapter 5 Specifications
Chapter 6 Defaults/Glossary
Chapter 7 Troubleshooting
Chapter 8 Spare Parts
1-1 General 4
1-2 Ordering Code 5
2-1 Unpacking 6
2-2 Mounting 6
2-3 Case Location 7
2-4 Wiring Precautions 8
2-5 Power Wiring 9
2-6 Sensor Installation Guidelines 10
2-7 Thermocouple Input Wiring 11
2-8 RTD Input Wiring 12
2-9 Linear DC Input Wiring 12
2-10 Alarm Relays 13
2-11 Changing the Chart 14
2-12 Marking Systems 14
2-13 Replacement of Pen Ink Style 15
2-13-1 Replacement of Thermal Head 16
2-14 Battery Backup 17
3-1-1 Single Pen Ink 18
3-1-2 Dual Pen “OEM” Ink 19
3-1-3 Dual Pen Universal Input Ink 20
3-1-4 Thermal Recorder 1&2 Pen 21
22
3-2-1 Ink Style 22
3-2-2 Thermal Style 23
4-1PenZeroandSpanInkStyle 24
4-2 Probe Offset Ink Style 25
4-3 Probe Offset Thermal Style 26
4-4 Thermal Contrast Adjustment 26
27
29
29
31
3

Chapter 1 Overview
1-1 General
The DR 5000 is a microprocessor based circle chart recorder.
Programmable alarm options combined with “ease of setup” provide the
flexibility required for multiple recording applications. This manual will
cover both ink type and thermal print versions.
The DR 5000 is the first recorder to “self document” setup configuration
during initial setup and can operate using standard or competitive charts.
The battery backup option (on ink type units) provides up to 48 hours of
recording in the event of power loss, thereby providing an additional
degree of protection for customer processes. The Green LED indicates
battery condition, see section 2-14.
The Thermal print version offers a single chart inventory for all recording
needs. “Print your own” chart technology includes real time trend and
printed time and date directly on the chart. The Thermal Recorder
provides dual channel recording as standard. Each channel is
configurable for universal inputs. Unit can easily be configured, in field,
to single channel via keypad.
The unit is powered by 110/220VAC, 50/60Hz. Programmable inputs for
thermocouple types J, K, T, R, B and S as well as 4-20mA or VDC are
standard. Optional alarm relays are available and programmable for
low, high or band operation. The Green LED indicates unit is powered.
A unique setup chart provides the user with an “on the spot” manual.
This setup chart will also self document the current setup for quick
review by an operator.
High accuracy, maximum flexibility, fast response and a simple user
interface are the main benefits of the DR 5000 recorder.
4

1-2 Ordering CodeDR 50001-2 Ordering CodeDR 5000
DR 5000DR 5000
Power Input
Recording Style
Outputs
Display Options
Chart Option
Enclosure Options
Special Options
1: 110/220VAC 50/60HZ
Selectable
1:1PenInk
2:2PenInk
3: Thermal Print Recorder *
5:2PenOEM**(InkStyle)
6:2PenOEM**(InkStyle)
0: None
1: 1 Relay, DPDT 1A/240VAC resistive***
2: 2 Relay, DPDT 1A/240VAC resistive***
0: None
1: 10” Counterclockwise Rotation
2: 10” Clockwise Rotation
“Counterclockwise ONLY on thermal units”
1: Standard (Nema 3)
2: Nema 4X
3: Platen Mount
0: None
1: Battery Backup****
Suffix Blank Standard Namestrip
Suffix AA-ZZ Door Namestrip Identifier
*
OEM Units - No Relays are allowed on OEM units.
Code5-Pen1UniversalInput, Pen 2 4/20 ma,1/5 VDC
Code6-Pen1UniversalInput, Pen 2 0/5 VDC, 0/20 ma
*** Recording style 1 and 2 only allow 1 relay per pen.
**** Ink Recorders ONLY. Allows 48 hours of continuous
Recording upon power loss.
Thermal Version units UL/CUL Pending. Thermal recorder comes
standard as dual channel recorder. Unit can be configured, in field
to a single channel via keypad.
**
5

Chapter 2 Installation
To minimize the possibility of fire or shock hazards, do not
expose this instrument to rain or excessive moisture.
Do not use this instrument in areas under hazardous
conditions such as excessive shock, vibration, dirt, moisture,
corrosive gases or oil. The ambient temperature of the areas should
not exceed the maximum rating specified in Chapter 5.
2-1 Unpacking
Upon receipt of the shipment remove the unit from the carton and
inspect the unit for shipping damage.
If any damage due to transit , report and claim with the carrier.
Write down the model number, serial number, and date code for
future reference when corresponding with our service center. The
serial number (S/N) and date code (D/C) are labeled on the box and
the bottom side of the recorder. Make sure that all items are
accounted for:
1: Battery (for optional battery backup)
2: Ferrite Bead
3: Installation manual
2 - 2 Mounting
Make panel cutout to dimension shown in Figure 2.1.
Dangerous voltages capable of causing death are sometimes
present when wiring the instrument. Before installation or
beginning any troubleshooting procedures the power to all
equipment must be switched off and isolated. Units suspected of
being at fault must be disconnected and removed to a properly
equipped workshop for testing and repair. Component replacement
and internal adjustments must be made by qualified personnel
only. This recorder operates on 110 or 220 (50-60hz), be sure line
voltage is OFF before connecting recorder.
This symbol represents Earth Ground connection
6

Install both mounting clamps and insert the case into panel cutout.
Figure 2.1 Mounting Diagram
Upon unpacking, find a suitable location to mount the recorder
before wiring power to the unit. After the recorder has been
connected to the main AC power supply, connect the battery
(optional) to the battery strap and place the battery in it’s holder.
Select a location that is well lighted, free from dust, dirt or
corrosive fumes. The instrument should not be located near any
sources of heat or be subject ot sudden or extreme temperature
changes. It should be mounted on a rigid support that is not
subject ot vibration. Refer to figure 2.1 for recorder case
dimensions.
2 - 3 Case Location
*
7

Unused control terminals should not be used as jumper points as
they may be internally connected, causing damage to the unit.
*
Verify that the ratings of the output devices and the inputs as
specified in Chapter 5 are not exceeded.
*
Electric power in industrial environments contains a certain
amount of noise in the form of transient voltage and spikes. This
electrical noise can enter and adversely affect the operation of
microprocessor-based controls. For this reason we strongly
recommend the use of shielded thermocouple extension wire
which connects the sensor to the unit. This wire is a twisted-pair
construction with foil wrap and drain wire. The drain wire is to be
attached to earth ground at the sensor end only.
*
2 - 4 Wiring Precautions
Before wiring, verify the label for correct model number and
options. Switch off the power when checking.
*
Care must be taken to ensure that maximum voltage rating
specified on the label are not exceeded.
*
It is recommended that power of these units to be protected by
fuses or circuit breakers rated at the minimum value possible.
*
All units should be installed inside a suitably grounded metal
enclosure to prevent live parts being accessible from human
hands and metal tools.
*
All wiring must conform to appropriate standards of good practice
and local codes and regulations. Wiring must be suitable for
maximum voltage, current, and temperature rating of the system.
*
Take care not to over-tighten the terminal screws.
*
8

The recorder uses AC power when it is operating normally. The battery back-up
option on ink recordesr will allow the recorder to operate for approximately 48
hours in case of a power loss. AC input can be fused with a 250VAC, .5 Amp fuse.
In order to connect the recorder to the main AC power, you must first gain access to
the microprocessor PC board that is mounted to the back of the chart plate. Your
recorder will have a hinged chart plate held in place by two (2) screws located on
the right hand side of the chart plate. Remove these two screws and open the
hinged chart plate. If you are not sure how to access the back of the chart plate,
please contact FUTURE DESIGN CONTROLS before continuing.
The AC power connections are made to the 4 pin terminal block located on back
side of platen. All AC and ground wires must be a minimum of 16 AWG.
Refer to Figure 2.2 for proper connection to the main AC power.
Earth Ground must be connected at ground lug provided. See Figure 2.2
This equipment is designed for installation in an enclosure which provides
adequate protection against electric shock. Grounding of thisrecorder must meet
national and local codes. Ground wire should be Color coded GREEN or GREEN
with a YELLOW stripe.
Local requirements regarding electrical installation should be rigidly
observed. Consideration should be given to prevent unauthorized persons
access to the power terminals.
2-5 Power Wiring
The unit is supplied to operate at 110/220VAC 50/60Hz. Check that the
installation voltage corresponds with the power rating indicated on the
product label before connecting power to the unit.
Figure 2.2
Power Supply
AC Input Terminal
220 VAC Wiring
L1
L2
T1
T2
T3
T4
110 VAC Wiring
AC Input Terminal
L1
L2
T1
T2
T3
T4
Earth Ground
Connection
Earth Ground
Connection
9

Proper sensor type is also a very important factor to obtain precise
measurements. The sensor must have the correct temperature range to
meet the process requirements. In special processes the sensor might
need to have different requirements such as leak-proof, anti-vibration,
Standard thermocouple sensor limits of error are 4 degrees F
( 2 degrees C ) or 0.75% of sensed temperature plus drift caused by
improper protection or an over-temperature occurrence. This error is far
greater than controller error and cannot be corrected at the sensor except
by proper selection and replacement.
In order to connect the probe input device to the recorder, you must first
gain access to the microprocessor PC board that is mounted to the back
of the chart plate.
CAUTION! DO NOT TOUCH the terminals of the transformer
while the recorder is connected to the main AC power supply. To avoid the
risk of possible electric shock, unplug or disconnect the recorder from
the main power supply before attempting to open the recorder. If the
recorder is installed with the battery back-up option, disconnect the 9 Volt
battery to avoid damaging the recorder and draining the battery.
Your recorder will have a hinged chart plate held in place by two (2)
screws located on the right hand side of the chart plate. Remove these
two screws and open the hinged chart plate. If you are not sure how to
access the back of the chart plate, please contact FUTURE DESIGN
CONTROLS before continuing.
Proper sensor installation can eliminate many problems in a control system.
The probe should be placed so that it can detect any temperature change
with minimal thermal lag. In a process that requires fairly constant heat
output, the probe should be placed close to the heater. In a process where
the heat demand is variable, the probe should be close to the work area.
Some experiments with probe location are often required to find this
optimum position.
2-6 Sensor Installation
A ferrite bead has been included to provide additional protection for
electrical “Noise” sensor signal wires can pick up. See drawing below for
correct installation of this device. Figure 2.3
Ungrounded thermocouples recommended on 2 pen units.
Sensor wire in Sensor wire out
to Input terminal
Ferrite Bead
Figure 2.3
10