weschler instruments BG Series User manual

WESCHLER INSTRUMENTS
DIVISION OF HUGHES CORPORATION
OWNERS
MANUAL
for
BG Series
REVISION 2.8 10/17
16900 Foltz Industrial Parkway, Cleveland, Ohio 44149
Phone: [phone] Fax: [phone]
Email: [email protected]

Contents
1 INTRODUCTION ............................................................................................................................. 1
2FEATUREDESCRIPTIONS .............................................................................................................. 2
BarGraphProtection......................................................................................................................... 2
BarDisplay ...................................................................................................................................... 2
DigitalDisplay .................................................................................................................................. 2
Trend Indicators(Option) ................................................................................................................. 3
Setpoints(Option) ............................................................................................................................ 3
TemperatureMeasurement................................................................................................................ 4
Hysteresis......................................................................................................................................... 4
Retransmit(Option) .......................................................................................................................... 4
Peak/Valley(Option) ........................................................................................................................ 4
Power .............................................................................................................................................. 4
3INSTALLATION................................................................................................................................5
Verification ....................................................................................................................................... 5
Mounting .......................................................................................................................................... 5
ElectricalHookup ............................................................................................................................. 6
4SETUP ............................................................................................................................................... 7
NormalDisplayOperation ................................................................................................................ 7
DisplayOperationDuringSetup ........................................................................................................ 7
OperatorandSupervisorSetup......................................................................................................... 8
4.1OPERATORSETUPPROGRAMMING......................................................................................... 9
ActivatingOperator Setup ................................................................................................................ 9
OperatorSetupActions .................................................................................................................... 9
AlarmSetpoints .............................................................................................................................. 10
4.1.1FAILSAFESETPOINT SETUP PROCEDURE ......................................................................... 11
HighSetpoint.................................................................................................................................. 11
LowSetpoint.................................................................................................................................. 11
4.2SUPERVISORSETUPPROGRAMMING ................................................................................... 12
ActivatingSupervisorSetup ............................................................................................................ 12
SupervisorSetupFunctions............................................................................................................. 12
AlarmSetpoints .............................................................................................................................. 14
Enable/DisablePeak/Valley ............................................................................................................. 15
SetHysteresis................................................................................................................................. 15
BarGraph™Zero ........................................................................................................................... 16
BarGraph™FullScale ................................................................................................................... 16
SetBarform.................................................................................................................................... 17
Enable/DisableOperatorSetup ....................................................................................................... 18
SetDecimalPoint ........................................................................................................................... 18
Set Bar Zero .................................................................................................................................. 19
SetBarFullScale ........................................................................................................................... 20
Set ID ............................................................................................................................................ 20

5 CALIBRATION ......................................................................................................................... 21
Calibration Procedure ............................................................................................................. 21
6 TEMPERATURE MEASUREMENT ....................................................................................... 24
7 ANALOG RETRANSMIT OPTION ........................................................................................ 25
Analog Retransmit Output Options ...................................................................................... 25
7.1 ANALOG RETRANSMIT CALIBRATION ........................................................................ 26
7.2 ISOLATED ANALOG RETRANSMIT CALIBRATION ................................................... 27
8 PEAK/VALLEY OPTION......................................................................................................... 29
Valley Display ........................................................................................................................ 29
Valley Capture Cycle ............................................................................................................. 29
Valley Reset ............................................................................................................................ 29
Peak Display ........................................................................................................................... 29
Peak Capture Cycle ................................................................................................................ 29
Peak Reset ............................................................................................................................... 29
9 REPLACEMENT PARTS.......................................................................................................... 30
10 WARRANTY ........................................................................................................................... 31
Appendix I - BARGRAPH RETROFIT GUIDE ........................................................................ 32
Appendix II - TERMINAL CONNECTIONS ............................................................................ 33
BG-252, BH-252, BD-101, PC-101, PH-101, PG-101 & PG-202 ........................................ 33
BG-241, 251, 261 & 281 ......................................................................................................... 34
Terminal Barrier Strip Option (BG-241, 251, 261 & 281) .................................................... 35
Line Frequency and Synchroscope (BG-241, 251, 261 & 281) ........................................... 36
Wattmeter Wiring (BG-241, 251, 261 & 281) ....................................................................... 37
Varmeter Wiring (BG-241, 251, 261 & 281) ......................................................................... 38
Power Factor Meter Wiring (BG-241, 251, 261 & 281) ........................................................ 39
RS-485 Communications Cabling ......................................................................................... 40
Appendix III - SPECIFICATIONS .............................................................................................. 41
Appendix IV - CIRCUIT BOARD LAYOUT DRAWINGS ..................................................... 42
BG-252, BH-252, BD-101, PC-101, PH-101, PG-101 & PG-202 ........................................ 43
BG-241, 251, 261 & 281 ......................................................................................................... 44
Option 4 Module (Isolated Analog Retransmit) ................................................................... 45
Appendix V - PHYSICAL DIMENSIONS.................................................................................. 46
BG-241, 251, 261 & 281 ......................................................................................................... 46
BG252 ..................................................................................................................................... 47
PC-101 and PC-202................................................................................................................. 47

1
1 INTRODUCTION
Weschler Instruments offers a complete line of BarGraph™ instruments that fit many existing analog
meter cutouts (see Appendix I) and can operate with the same input signals. They provide enhanced
features,such as peak/valley hold, retransmit,computer communication, plus multiple barand digital
displaycolorsandcombinationstomeetcustomer-specificengineeringconsiderations. Detailed speci-
fications are listed in Appendix III.
This manual covers the following standard BarGraph models from Weschler Instruments:
BG-251 6" Round BarGraph
BG-281 8" Round BarGraph (pictured)
BG-241 41/2" Square BarGraph
BG-261 81/2" Square BarGraph (pictured)
BH-252 6" Horizontal BarGraph (pictured)
PH-101 DIN (72 X 144 mm) Horizontal BarGraph
PC-202 DIN (72 X 144 mm) Dual Vertical BarGraph (pictured)
ML-202 DIN (72 X 144 mm) Dual Vertical BarGraph
PG-202 10" Dual Vertical BarGraph
BG-252 6" Vertical BarGraph (pictured)
BW-1316 6" Vertical BarGraph
PG-101 10" Vertical BarGraph
PC-101 DIN (72 X 144 mm) Vertical BarGraph

2
2 FEATURE DESCRIPTIONS
Weschler BarGraphs are internally protected against power and input surges. The power supply
integrates a fuse and MOV to insure that no circuit damage occurs. Input surges are virtually elimi-
nated by internal CTs and PTs (for AC) and a clamping circuit (for DC). For maximum limits, see
Appendix III, Specifications.
When measurements such as Retransmit and Communication are read from the BarGraph, the out-
puts are directly driven. The user should provide safeguards to prevent ground loops when using
these options.
Warning: Review Section 3, Installation, to insure that the proper inputs
and options were ordered and received. Connecting a BarGraph in the
wrong application may cause damage to the instrument!
Bar Display
The bar display consists of either 51 segments (PG-101 and PG-202) or 101 segments (all others).
The segments are either red (standard) or green (optional). Multi-color and amber bar displays are
alsoavailable.
The zero point can be set so that the bar scale begins indicating anywhere from the bottom to the top
of the instrument. The zero can also be set to a location that is not visible on the bar, to allow an
expanded indication. For process applications where the zero point could vary, simple programming
can give the user selections of 25%, 33%, 50%, or 100% from the bottom of the bar scale. Typical
applications that require an elevated zero point are: center frequency deviation (center zero - 50%),
vacuum measurements (25% and 33%), and mineshaft and elevator location (top zero - 100%).
Digital Display
The BarGraph can be combined with a seven segment, 3-1/2 digit (-1,999 to 1,999) or 4-1/2 digit
(-19,999 to 19,999) LED digital display to increase usefulness and instrument resolution. The digital
display is a dynamic option of the BarGraph since all readings can be in direct or engineering units
related to any input signal. The analog trend on the bar graph can be seen at a glance, but when
critical measurements or fine tuning are required, the digital display has a resolution of up to 0.01%.
The standard color for the digital display is red, with green or amber available as options.
BarGraph Protection

3
Trend Indicators (Option)
The BarGraph provides visual indication of the process signal direction. The annunciator arrows on
the front of the BarGraph are red or green LEDs that respond to changes in input signal at a rate
corresponding to the programmed hysteresis.
Setpoints (Option)
The setpoint option converts a BarGraph from an indicator to a differential gap or on/off-style con-
troller. The BarGraph accommodates up to four setpoint locations: Hi/Hi, Hi (alarms when the signal
is higher than one of two Hi setpoint values), Lo, and Lo/Lo (alarms when the signal is below one of
two low setpoint values).
When any of the alarm values are met, alarm annunciators on the front of the BarGraph light and
form “C” relays close. The relay contacts can be used to sound alarms or control the process.
To identify each setpoint location in relationship to the displayed input signal, each LED segment
representing the setpoint value will be illuminated when the signal is less than the setpoint value or
non-illuminated when the signal is greater than the setpoint value. When the input signal is at a value
corresponding to one LED segment above or below the LED segment representing the setpoint
value, the setpoint LED segment will flash at a 1 Hertz rate. When the input signal value corresponds
to the setpoint LED segment exactly, the LED segment will flash at a 2 Hertz rate.

4
Temperature Measurement
Weschler BarGraphs may be used to measure temperature using either thermocouples or RTDs
(Resistive Thermal Devices). Thermocouples consist of two dissimilar metals joined so that a poten-
tial difference is generated that is a measure of temperature. RTDs depend on the fact that the
resistance of any metal increases as the temperature increases.
When configured to use RTDs, Weschler BarGraphs provide a fixed current source to drive the
RTD. When configured to work with thermocouples, Weschler BarGraphs have internal cold junc-
tion compensation and ice point reference. The BarGarph is linearized for the specified thermo-
couple (J, K, or T) on the order.
Hysteresis
Instrument hysteresis (deadband) can be set at 0.5%, 1%, or 2% of full scale. The hysteresis setting
provides a faster or slower response to the trend indicators and setpoints. Other values are possible;
please contact the factory for special requirements.
Retransmit (Option)
The BarGraph provides a retransmitted signal (4-20 mA, 0-1 mA, 1-5 VDC, or 0-1 VDC) directly
proportional to the zero and full scale of the LED bar indicator. All retransmit signals are factory-set
and only need to be verified at installation, even if the input is rescaled.
Peak/Valley (Option)
The Peak/Valley option allows the BarGraph to display the highest (Peak) and lowest (Valley) levels
during the reading cycle, as determined by the reset.
Power
All BarGraphs have self-contained power supplies which can be powered by 120/240VAC (50/60/
400Hz). DC-powered Bar Graphs can be powered by 5 V (±5%) @ 400 mA, 8 to 50 V, 125 V, or
250V(+10%).Instrumentisolationisaccomplished via the power supply transformer for AC sources.
Differential input signal conditioning provides common mode rejection of greater than 80 dB.

5
3 INSTALLATION
Remove the BarGraph instrument from its packing container. Check to make sure that the
BARGRAPH LABEL (shown below) on the BarGraph and packing container are identical. Verify
that the BarGraph number received is what is required for your application. Please verify this num-
ber with your purchase order.
Warning: insure that the proper inputs and options were ordered and
received. Connecting a BarGraph in the wrong application may cause dam-
age to the instrument!
Verification
Meter Label
Mounting
1. Securely mount the BarGraph to the panel using the hardware provided. Panel cutout dimen-
sions for each model are provided in Appendix V.
Torque requirements for BG-241, BG-251, BG-261 and BG-281 are 65-70 inch-pounds maxi-
mum.
For BG-252, tighten the screw no more than two turns after the screw point contacts the panel.
2. BG-252 Only: Install the meter trim to the front bezel.

6
Electrical Hookup
Electrical connections should be made after the BarGraph has been mounted. Refer to terminal
connection diagrams in Appendix II.
1. Connect the power supply to the appropriately labeled terminals. The proper power supply
depends on the model BarGraph ordered. Available power supply options are:
• 120 VAC
• 240 VAC
• 5-12 VDC
• 13-50 VDC
• 110-170 VDC
• 110-250 VDC
2. Connect the signal input leads to the proper terminals. The proper input terminals depend on the
model BarGraph ordered. Available input options are:
Input 1 - Voltage or Current, AC or DC
Input 2 - RTD, Magnetic Pickup, J, K, or T Thermocouples
Input 3 - Frequency
Input 4 - 3-phase voltage or current
3. If the retransmit option was ordered, connect the analog retransmit signal output. Output levels
of the retransmit option depend on the model BarGraph ordered. Available output level options
are:
• 4-20 mADC
• 0-1 mADC
• 1-5 VDC
• 0-1 VDC
3. If the serial communication option was ordered, connect the communication transmit and re-
ceive lines. Output levels of the serial communication option depend on the option ordered.
Available input/output options are:
• RS-232
• RS-422
• RS-485
4. If alarm setpoint options were ordered, connect the appropriate lines to the setpoint options.
Setpoint connections are clearly labeled for C (common), NO (normally open) and NC (nor-
mally closed. These connections are made to Form C relays within the BarGraph.

7
4 SETUP
Normal Display Operation
The bar and digital displays provide visual analog indication of the process signal. When the in-
coming signal is below the bottom end of the bar display, the first LED and the digital display flash
at a 1 Hz rate, indicating an underrange condition. When the process signal exceeds the full scale
value, the top LED and the digital display flash at a 1 Hz rate, indicating an overrange condition.
The bar and digital display can be inhibited from flashing in the underrange/overrange condition by
installing a permanent jumper on JA6. See Appendix IV, Circuit Board Layout Drawings, for the
locations of jumpers.
Display Operation During Setup
During setup programming, the bar and digital displays provide information to the user for pro-
gramming. The digital display is used to show simple 2-number abbreviations and numeric values
for each of the setup functions and the bar display is used to provide an analog indication of func-
tions and function values.
Information from the user is input through pushbuttons on the front panel of your BarGraph. To
access these pushbuttons on the BG-251, BG-261 and BG-281, the front cover must be removed.
There are three pushbuttons: INCREASE ( ), DECREASE ( ) and ENTER/SAVE ( ).