M/D TOTCO - xa.yimg.comxa.yimg.com/kq/groups/13724245/406055959/name/Digital_Gauge_I__… · Warnings against the use of specific service methods that can damage equipment or render

Printe d in U.S.A. Augu st 14, 1997

Manufacturers of Precis ion Instruments

M/D TOTCOINSTRUMENTATION

™

INSTALL ATION, OPERATION, AND MAINTENANCE

Digital Gauge I & II

P/N DG1-Series & DG2-Series

Part Number 26-102

Revision B

Manual 26-102 contains 225 pages as follows:

Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . August 1997iii through vi. . . . . . . . . . . . . . . . . . . . . . . . . . . . August 1997TOC-1 through TOC-6 . . . . . . . . . . . . . . . . . . . August 1997LOF-1 through LOF-2 . . . . . . . . . . . . . . . . . . . . August 1997LOT-1 through LOT-2 . . . . . . . . . . . . . . . . . . . . August 19971-1 through 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . August 19972-1 through 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . August 19973-1 through 3-56 . . . . . . . . . . . . . . . . . . . . . . . . August 19974-1 through 4-52 . . . . . . . . . . . . . . . . . . . . . . . . August 1997A-1 through A-16 . . . . . . . . . . . . . . . . . . . . . . . August 1997B-1 through B-8 . . . . . . . . . . . . . . . . . . . . . . . . August 1997C-1 through C-10 . . . . . . . . . . . . . . . . . . . . . . . August 1997D-1 through D-10 . . . . . . . . . . . . . . . . . . . . . . . August 1997E-1 through E-2 (plus drawings) . . . . . . . . . . . . August 1997F-1 through F-2 (plus drawings) . . . . . . . . . . . . August 1997

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.

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 14, 1997 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 14, 1997M/D TOTCO

TABLE OF CONTENTS

Paragraph/Title Page

CHAPTER 1 INTRODUCTION

1-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-2 SCOPE OF MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-3 INTENDED AUDIENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-4 PERSONNEL QUALIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-5 NOTES, CAUTIONS, AND WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

CHAPTER 2 OVERVIEW

2-1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1-1 Front Panel Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

CHAPTER 3 INSTALLATION

3-1 INSTALLATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-2 MOUNTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-2-1 Box Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-2-1-1 Direct Mount With Attached Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-2-1-2 Mount With Brackets - External Powered or Battery Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-2-2 Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-2-2-1 Panel Mounting - Six inch Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-2-2-2 Panel Mounting - Ten inch Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-3 CABLE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3-4 POWER REQUIREMENTS FOR INTRINSICALLY SAFE OPERATIONS . . . . . . . . . . . . . . . .3-9

3-4-1 Unregulated Power - 9-36VDC or 120/240 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-4-2 Regulated 12 Volt Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-4-3 Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3-5 POWER REQUIREMENTS FOR NON-INTRINSICALLY SAFE OPERATIONS. . . . . . . . . . .3-13

3-5-1 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3-5-1-1 Power Input Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3-6 ALARM CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3-6-1 Digital Gauge & Horn (DIV 1/Zone 0), Barrier (Safe Area) . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3-6-2 Digital Gauge (DIV 1/Zone 0) & Horn/Barrier (DIV 2/Zone 2) . . . . . . . . . . . . . . . . . . . . . . . . .3-19

3-6-3 Digital Gauge (DIV 1/Zone 0) & Barrier and Horn (Safe Area) . . . . . . . . . . . . . . . . . . . . . . . .3-19

3-6-4 Digital Gauge & Horn (Safe Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3-7 SERIAL COMMUNICATION - RS485 LINK (DIGITAL II ONLY) . . . . . . . . . . . . . . . . . . . . . . .3-20

3-7-1 Gauge to Gauge in Hazardous Areas (Digital Gauge II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

August 14, 1997 TOC-1M/D TOTCO

Digital Gauge I & IIManual 26-102 Table of Contents


3-7-2 Gauge in Hazardous Area to Gauge in Safe Area Installation . . . . . . . . . . . . . . . . . . . . . . . .3-23

3-8 SENSOR WIRING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

3-8-1 Analog Sensor - Pressure Transducer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

3-8-2 Analog Sensor - Strain Gauge Bridge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

3-8-3 Analog Sensor 0-5 Volt Potentiometer (3-wire) Installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3-8-3-1 Pit Probe Wiring (P/N 262622-Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

3-8-3-2 Pit Probe Wiring (P/N H10941A-Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

3-8-3-3 Pit Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

3-8-3-4 Flow Sensor Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

3-8-3-5 Flow Sensor Preliminary Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

3-8-3-6 Flow Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35

3-8-3-7 Flow Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

3-8-4 4-20mA Sensor (Customer Supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

3-8-5 Hookload/Line Tension Transducer Sensor - (4-20mA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

3-8-6 Hookload/Line Tension Transducer Sensor Powered by Adjustable 24 V Supply . . . . . . . . .3-40

3-8-7 Digital Gauge Connected to a 4-20mA Sensor via a UL DAQ . . . . . . . . . . . . . . . . . . . . . . . .3-41

3-8-8 Digital Gauge Connected to a 4-20mA Sensor via a Barrierless DAQ (Non U.L.) . . . . . . . . .3-42

3-8-9 Digital Input - Proximity Sensor (Low Frequency Applications- 70 Hertz) . . . . . . . . . . . . . . .3-43

3-8-9-1 Digital Input - Proximity Sensor (High Frequency Application - 1000 Hertz) . . . . . . . . . . . . . .3-45

3-8-9-2 Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47

3-8-10 Digital Gauge To DAQ Installation (UL DAQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48

3-8-11 Digital Gauge Connected to Barrierless (Non U.L.) DAQ with Digital Output . . . . . . . . . . . . .3-50

3-9 NON-ISOLATED DIGITAL CONNECTION (SAFE AREA) . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51

3-9-1 Non-Isolated Digital Connection - External Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51

3-9-2 Non-Isolated Digital Connection - Battery Powered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52

3-10 ISOLATED DIGITAL CONNECTION (SAFE AREA) - BATTERY OR EXTERNAL PWR . . . .3-53

3-11 ANALOG OUTPUTS (DIGITAL GAUGE II ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54

3-11-1 4-20mA Output Connection (Non I.S.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56

CHAPTER 4 OPERATIONS

4-1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1-1 Front Panel Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-1-2 Active Viewing Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4-1-3 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-2 ANALOG CHANNEL SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-2-1 Analog Application - Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-2-1-1 Configure Analog Channel Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

TOC-2 August 14, 1997M/D TOTCO

Digital Gauge I & IITable of Contents Manual 26-102


4-2-1-2 Analog Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-2-1-2-1 M/D TOTCO Transducer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4-2-1-2-2 Calibration of 0-5 Volt, 2 m/V Strain Gauge, and 4-20mA Sensors . . . . . . . . . . . . . . . . . . . 4-11

4-2-2 Special Engineering Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-2-2-1 Maximum Channel Value Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

4-2-2-2 Minimum Channel Value Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

4-2-2-3 Multiply Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

4-2-2-4 Divide Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4-2-2-5 Offset Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

4-2-2-6 Set Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4-2-3 Sensor Location Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4-3 DIGITAL CHANNEL SET-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

4-3-1 Digital Application - Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

4-3-1-1 Configure Digital Channel Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

4-3-1-2 Digital Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

4-3-1-3 Decimal Point Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

4-3-1-4 Minimum Channel Value Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

4-3-2 Sensor Location Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

4-4 CALCULATED CHANNELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

4-4-1 Ton Mile Channel Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

4-5 USER FUNCTIONS MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32

4-5-1 Sensor Alarm Setting - HIGH/LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33

4-5-2 Bar Graph Setup and Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35

4-5-3 Set Point Set-up and Modification- (FOR DIGITAL GAUGE (II) - ONLY) . . . . . . . . . . . . . . . .4-36

4-5-4 Dampener Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38

4-5-5 Peak Hold Feature (Digital Gauge II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39

4-5-6 BackLighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40

4-5-7 Battery Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40

4-5-8 Adjusting LCD contrast and Viewing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41

4-5-9 Software Version Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42

4-6 SPECIAL FUNCTIONS MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43

4-6-1 SET I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44

4-6-2 Analog to Digital Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45

4-6-3 Channel Name Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46




4-6-4 Erase All Stored Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47

4-6-5 Sender/Receiver Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48

4-6-6 View Internal Gauge Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-50

4-6-7 Battery Replacement or Changing from Battery Powered to External Powered . . . . . . . . . . .4-51

APPENDIX A PARTS LIST

A-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

A-2 DIGITAL GAUGE I ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

A-3 DIGITAL GAUGE II ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

A-4 SUCTION GRIP TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16

APPENDIX B SPECIFICATIONS

B-1 CERTIFICATION DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

B-2 HARDWARE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

B-2-1 Housing Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

B-2-2 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

B-2-3 Gauge Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

B-2-4 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

B-2-5 Operating/Storage Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

B-2-6 Power Source(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

B-2-7 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

B-2-8 Battery Life Expectancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

B-2-9 LCD Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

B-2-10 LCD Viewing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

B-3 ANALOG INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

B-3-1 Analog Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

B-3-2 Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

B-3-3 Analog Input Compatible Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

B-3-4 Strain Gauge Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

B-3-5 Pressure Transducer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

B-4 DIGITAL INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

B-4-1 Digital Input #1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

B-4-2 Digital Input #2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

B-4-3 Digital Input Compatible Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

B-5 ANALOG OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

B-5-1 Voltage Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

B-5-1-1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7


Digital Gauge I & IITable of Contents Manual 26-102


B-5-1-2 Compatible Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

B-5-2 4-20mA Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

B-5-2-1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

B-5-2-2 Compatible Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

B-5-3 Interface Configurations/ Barrier Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

APPENDIX C TROUBLESHOOTING

C-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

C-2 DIGITAL GAUGE DOES NOT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

C-3 ERROR CODE TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

C-4 BATTERY TEST PROCEDURE (P/N 221022-005). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

C-5 DIGITAL GAUGE CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

C-5-1 Alarm Relay Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

C-5-2 Sensor Input Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

C-5-3 Analog Output Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

C-5-4 Power Input Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7

C-6 CPU BOARD (DISPLAY & KEYPAD) REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8

C-7 CABLE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9

APPENDIX D MENU TREES

D-1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

D-2 DEFINITION OF SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

APPENDIX E CALIBRATION AND SET-UP PROCEDURES

E-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

E-2 LIST OF DRAWINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

APPENDIX F SYSTEM LEVEL DOCUMENTATION

F-1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

F-2 LIST OF DRAWINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1





LIST OF FIGURES


OVERVIEW

Figure 2-1. Digital Gauge I & II - Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1Figure 2-2. Digital Gauge - Backview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

INSTALLATION

Figure 3-1. Digital Gauge I Installation - Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1Figure 3-2. Digital Gauge II Installation - Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2Figure 3-3. Digital Gauge II Multi-Sensor Installation - Block Diagram . . . . . . . . . . . . . . . . . . . . . . .3-2Figure 3-4. Box Mount Screw Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4Figure 3-5. Box Mount Hole Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4Figure 3-6. 221033-001 Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5Figure 3-7. 221033-002 Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5Figure 3-8. 221033-003 Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5Figure 3-9. 221033-001 and 221033-002 Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6Figure 3-10. 221033-003 Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6Figure 3-11. Panel Mount Screw Locations (Six-Inch Bezel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7Figure 3-12. Panel Mount Hole Pattern (Six-inch Bezel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7Figure 3-13. Panel Mount Screw Locations (Ten-inch Bezel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8Figure 3-14. Panel Mount Hole Pattern (10-inch Bezel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8Figure 3-15. External Power (Intrinsically Safe Application) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10Figure 3-16. Regulated 12 Volt Power (Intrinsically Safe Application) . . . . . . . . . . . . . . . . . . . . . . .3-10Figure 3-17. Regulated 12 Volt Power (I.S. application - No backlighting) . . . . . . . . . . . . . . . . . . . .3-11Figure 3-18. Regulated 12 Volt Power (I.S. application - With backlighting) . . . . . . . . . . . . . . . . . . .3-11Figure 3-19. Battery Pack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12Figure 3-20. Wiring (Option 1)- Non-Intrinsically Safe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13Figure 3-21. Wiring (Option 2) - Non-Intrinsically Safe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14Figure 3-22. Digital Gauge I & II (Backview) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15Figure 3-23. Power Input Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17Figure 3-24. Alarm Device Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18Figure 3-25. Alarm Device Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19Figure 3-26. Alarm Device Installation (Div 1/Zone 0 and Safe Area Combination) . . . . . . . . . . . . .3-19Figure 3-27. Alarm Device Installation (Safe Area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20Figure 3-28. Sender/Receiver (Hazardous Location) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21Figure 3-29. Generic Wiring Diagram for 221311-XXX J Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22Figure 3-30. Hazardous to Safe Area Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23Figure 3-31. Pressure Transducer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25Figure 3-32. Wiring Diagram - Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26Figure 3-33. Strain Gauge Application - Tension Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27Figure 3-34. Wiring Diagram - Bridge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29Figure 3-35. Pit Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31Figure 3-36. Wiring Diagram - Pit Probe (P/N 262622-Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32Figure 3-37. Wiring Diagram - Pit Probe (P/N H10941A-XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33Figure 3-38. Flow Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34Figure 3-39. Wiring Diagram - Flow Sensor (P/N 270701-103) . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36Figure 3-40. Mud Flow Sensor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37Figure 3-41. 4-20mA Wiring Diagram (I.S. application) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37Figure 3-42. 4-20mA Wiring Diagram (Non-IS Application) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38Figure 3-43. Wiring Diagram - Hookload/Line Tension Transducer . . . . . . . . . . . . . . . . . . . . . . . . .3-39

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Digital Gauge I & IILIST OF FIGURES Manual 26-102

Figure 3-44. Hookload/Line Tension Sensor Powered an Adjustable Power Supply . . . . . . . . . . . .3-40Figure 3-45. Digital Gauge Connected to a 4-20mA Sensor via a U.L. DAQ . . . . . . . . . . . . . . . . . .3-41Figure 3-46. Digital Gauge Powered by 4-20mA Sensor via a Barrierless DAQ . . . . . . . . . . . . . . .3-42Figure 3-47. Proximity Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43Figure 3-48. Wiring Diagram - Proximity Sensor (Low Frequency 70 Hertz) . . . . . . . . . . . . . . . . . .3-44Figure 3-49. Wiring Diagram - Proximity Sensor (High Frequency 1000 Hertz) . . . . . . . . . . . . . . . .3-46Figure 3-50. Limit Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47Figure 3-51. Wiring Diagram - Limit Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47Figure 3-52. DAQ Installation (UL Certified DAQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48Figure 3-53. Wiring Diagram - DAQ to Digital Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49Figure 3-54. Digital Gauge Connected to Barrierless (Non-U.L.) DAQ . . . . . . . . . . . . . . . . . . . . . . .3-50Figure 3-55. Wiring Diagram - Non-Isolated Connection (Externally Powered) . . . . . . . . . . . . . . . .3-52Figure 3-56. Wiring Diagram - Non-Isolated Connection (Battery Powered) . . . . . . . . . . . . . . . . . .3-52Figure 3-57. Wiring Diagram - Isolated Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53Figure 3-58. Wiring Diagram -Analog 0-4.5 Volt Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54Figure 3-59. Wiring Diagram - Analog 4-20mA Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55Figure 3-60. 4-20mA Output Connection (Non-I.S.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56

OPERATIONS

Figure 4-1. Digital Gauge I & II - Front View (SEE NOTE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2Figure 4-2. Active Viewing Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3Figure 4-3. Operator Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4Figure 4-4. Analog Screen Example - Line Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6Figure 4-5. Special Engineering Line Equation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14Figure 4-6. Digital Screen Example - SPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23Figure 4-7. “NONE” Configuration Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49Figure 4-8. Sender/Receiver Configuration “A” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49Figure 4-9. Sender/Receiver Configuration “B” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49

PARTS LISTFigure A-1. Suction Grip Tool - P/N 999784-001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16

SPECIFICATIONS

Figure B-1. Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1Figure B-2. Ditigal Gauge I & II Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

TROUBLESHOOTINGFigure C-1. Alarm Relay Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4Figure C-2. Sensor Input Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5Figure C-3. Analog Output Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6Figure C-4. Power Input Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7Figure C-5. Suction Grip Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8

Page LOF-2 August 14, 1997M/D TOTCO

LIST OF TABLESParagraph/Title Page

OVERVIEW

Table 2-1. Digital Gauge Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

INSTALLATION

Table 3-1. Gauge Sensor Cable Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Table 3-2. Sensor to J-Box Cable Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Table 3-3. Junction Box Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Table 3-4. Cable Length Dash Number Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Table 3-5. Acceptable Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Table 3-6. Power Cable Assembly Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Table 3-7. Connector Designators and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Table 3-8. Power Input Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17Table 3-9. Barrier Safety Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17Table 3-10. M/D TOTCO Barrier Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18Table 3-11. Cable Assembly Part Number’s - Alarm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18Table 3-12. Relay Contact Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20Table 3-13. M/D TOTCO Pressure Transducer P/N’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25Table 3-14. Cable Assembly Part Numbers - Pressure Application . . . . . . . . . . . . . . . . . . . . . . . . 3-25Table 3-15. Strain Gauge Ohm Resistance and RCAL value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28Table 3-16. Cable Assembly Part Numbers - Pressure Application . . . . . . . . . . . . . . . . . . . . . . . . 3-29Table 3-17. Cable Assembly Part Numbers - Flow Sensor Application . . . . . . . . . . . . . . . . . . . . . 3-35Table 3-18. Cable Assembly Part Numbers for Proximity Application . . . . . . . . . . . . . . . . . . . . . . 3-45Table 3-19. Acceptable Proximity Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45Table 3-20. Cable Assembly P/N’s for Proximity Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . 3-46Table 3-21. Cable Assembly P/N’s for LImit Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48Table 3-22. Cable Assembly P/N’s for DAQ Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49Table 3-23. Power Cable Assemblies - DAQ to Digital Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50Table 3-24. Analog Output (0-4.5V) Cable Assembly P/N’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54Table 3-25. Analog Output (4-20mA) Cable Assembly P/N’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

OPERATIONS

Table 4-1. Default Analog Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Table 4-2. Channel and Required Sensor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Table 4-3. Default Digital Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22Table 4-4. Calculated Channels (Default). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

PARTS LIST

Table A-1. Digital Gauge I Assembly 221003-001 - Basic 6" Bezel . . . . . . . . . . . . . . . . . . . . . . . . A-3Table A-2. Digital Gauge I Assembly 221003-002 - 6" Bezel with Backlit LCD . . . . . . . . . . . . . . . A-4Table A-3. Digital Gauge I Assembly 221003-003 - 6" Bezel with Battery Pack. . . . . . . . . . . . . . . A-5Table A-4. Digital Gauge I Assembly 221003-004 - Basic 10" Bezel . . . . . . . . . . . . . . . . . . . . . . . A-6Table A-5. Digital Gauge I Assembly 221003-005 - 10" Bezel with Bacllit LCD . . . . . . . . . . . . . . . A-7Table A-6. Digital Gauge I Assembly 221003-006 - 10" Bezel with Battery Pack. . . . . . . . . . . . . . A-8Table A-7. Digital Gauge II Assembly 221010-001 - Basic 6" Bezel. . . . . . . . . . . . . . . . . . . . . . . A-10Table A-8. Digital Gauge II Assembly 221010-002 - 6" Bezel with Backlit LCD . . . . . . . . . . . . . . A-11Table A-9. Digital Gauge II Assembly 221010-003 - 6" Bezel with Battery Pack . . . . . . . . . . . . . A-12

August 14, 1997 Page LOT-1M/D TOTCO

Digital Gauge I & IILIST OF TABLES Manual 26-102

Table A-10. Digital Gauge II Assembly 221010-004 - Basic 10" Bezel. . . . . . . . . . . . . . . . . . . . . . A-13Table A-11. Digital Gauge II Assembly 221010-005 - 10" Bezel with Backlit LCD . . . . . . . . . . . . . A-14Table A-12. Digital Gauge II Assembly 221010-006 - 10" Bezel with Battery Pack . . . . . . . . . . . . A-15

SPECIFICATIONS

Table B-1. Operating/Storage Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2Table B-2. Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2Table B-3. Battery Life Expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3Table B-4. LCD Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3Table B-5. Analog Input Compatible Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4Table B-6. 2mv/V Strain Gauge Ohm Resistance and RCAL value . . . . . . . . . . . . . . . . . . . . . . . . B-4Table B-7. Pressure Transducer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5Table B-8. Digital Input Compatible Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6Table B-9. Voltage Output Compatible Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7Table B-10. 4-20 mA Output Compatible Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8Table B-11. Interface Configurations/Barrier Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

TROUBLESHOOTING

Table C-1. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1Table C-2. Digital Gauge I & II Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2Table C-3. Alarm Relay Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4Table C-4. Sensor Input Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5Table C-5. Analog Output Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6Table C-6. Power Input Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7Table C-7. Cable Length Dash Number Designators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9

MENU TREES

Table D-1 Definition of Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

CALIBRATION AND SET-UP PROCEDURES

Table E-1. List of Procudures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

SYSTEM LEVEL DOCUMENTATION

Table F-1. Drawings List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

Page LOT-2 August 14, 1997M/D TOTCO

CHAPTER 1INTRODUCTION

1-1 Introduction

This manual contains installation, operation, maintenance and parts information for the electronic Digital Gauge I and Digital Gauge II. Information in this manual should enable qualified personnel to install, operate and troubleshoot this system.

1-2 Scope of Manual

This manual is divided into the following chapters:

• Chapter 1 - Introduction

• Chapter 2 - Overview

• Chapter 3 - Installation

• Chapter 4 - Operation

• Appendix A - Illustrated Parts Breakdown and recommended spare parts inventory

• Appendix B - Specifications

• Appendix C - Troubleshooting

• Appendix D - Menu Trees

• Appendix E - Calibration and Set-up Procedures

• Appendix F - System Level Documentation

1-3 Intended Audience

This manual is intended for use by field engineering, installation, operation and repair personnel.

1-4 Personnel Qualifications

The procedures described in this manual should be performed only by persons who have read the safety notice on page i of this manual and who are fully qualified and trained to perform the proce-dures in this manual.

August 14, 1997 Page 1-1M/D TOTCO

Chapter 2 Digital Gauge I & IIOVERVIEW Manual 26-102

1-5 Notes, Cautions, and Warnings

Notes, 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.

FIGURE 1

TABLE 1

NOTE

Provides additional information about the current topic.

CAUTION

Provides 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 14, 1997M/D TOTCO

CHAPTER 2OVERVIEW

2-1 Overview

The M/D TOTCO Digital Gauge family gives you the power and precision of digital technology in a standard size 6” gauge housing. Digital Gauge I allows you to input and view either one digital or one analog channel.

Digital Gauge II allows you to input two digital and one analog channel while viewing any one at a time. Digital Gauge II also provides two analog outputs, an alarm relay output, and calculated channel capability.

All Digital Gauges can be powered externally or by an optional battery pack. Backlighting is an option available for both models. However, units equipped with a backlit LCD cannot be powered from a battery, and must be powered by an external power supply.

2-1-1 Front Panel Screen

Figure 2-1. Digital Gauge I & II - Front View

SET-POINT INDICATOR (DIGITAL GAUGE II ONLY)

BAR GRAPH LIMIT BAR GRAPH LIMIT

ALPHA WINDOW

LOW BATTERYINDICATOR

BAR GRAPHOVER-RANGEINDICATOR

ALARM

DIGITALVALUE

MODE ACKNOWLEDGE

SCROLL-DOWNSCROLL-UP

ON/OFF

TRENDARROWS

(DIGITAL GAUGE II ONLY)



Table 2-1. Digital Gauge Features

Gauge Face Features Description

ON/OFF Actuator button used to turn Digital Gauge on or off. (To turn off gauge, operator must press the ON/OFF button twice)

Scroll-Up Actuator button used to scroll through various menus or increase numeric calibration values.

Mode Actuator button acts as an ESC (escape) or back-up key. This key is used after steps are completed and the procedure requires returning to the previous screen.

Digital Value LCD digits used to display numeric values. Window used to display parameter current value or calibration data.

Low Battery Indicator Indicator light used to notify operator that the battery has been 90% expended and needs replacement.

Alpha Window LCD digits used to display alpha information. Window used to display channel names and menu structure.

Bar Graph Limit LCD digits used to display lower and upper limits of bar graph. Limits are operator setable.

Set-Point Indicator Indicator arrow used to reference a center point within a specified range. The operator can monitor the delta (devia-tion) from the set point. (For example: gain/loss)

Bar Graph Over-Range Indicator

Indicator arrow located on each end of the bar graph used to notify the operator that the displayed value is either above or below the limit values of the bar graph.

Alarm Indicator bell used to notify the operator that the Digital Gauge has exceeded an alarm limit- either Low or High arrows.

Trend Analysis Indicator arrows used to notify the operator the upward trend or downward trend of the current value as referenced from the previous value.

Acknowledge Actuator button used as an enter key. By pressing the ACK key, numeric values are acknowledged or the device is instructed to proceed forward.

Scroll Down Actuator button used to scroll through various menus or decrease numeric calibration values

*

* Digital Gauge II only

*


Digita l Gauge I & II Chapter 2Manual 26-102 OVERVIEW

PO

ALA

R

D

Figure 2-2 . Digital Gauge - Backview

WER SUPPLY CONNECTOR

SENSOR CONNECTOR

RM RELAY CONNECTOR

ANALOG OUTPUT CONNECTO

BATTERY PACK(not shown)

J1EXTERNAL POWER

EARTH GND BARRIER GNDJ2 J3 J4

EARTH GROUND

BARRIER GROUN

August 14 , 1997 Page 2-3M/D TOTCO



August 14, 1997 Page 3-1

CHAPTER 3INSTALLATION

3-1 Installation Overview

Digital Gauge I supports one channel input, either analog or digital. Specific channel names are assigned to the selected channel via the Add Channel section described in Chapter 4.

Figure 3-1. Digital Gauge I Installation - Block Diagram

Digital Gauge II supports up to three channel inputs, one analog and two digital. Additionally, one calculated channel can be added. Specific channel names are assigned to the analog and digital inputs via the Add Channel described in Chapter 4.

Digital Gauge II allows separate alarm limits (both High and Low) to be set for each of the three channel inputs, as well as the calculated channel. When an alarm condition occurs, the channel in alarm is automatically displayed and the alarm relay output contacts are activated.

Digital Gauge II allows Analog outputs (0-4.5V or 4-20mA-externally sourced) to duplicate the ana-log input channel and interface to an external device, such as a chart recorder. The analog output is scaled via the minimum and maximum channel values described in Chapter 4.

NOTE

Digital Gauge II has only one relay output available. Exceeding either ahigh or low alarm limit will activate this relay.

DIGITAL INPUT

ANALOG INPUT

EXTERNAL POWER (or)BATTERY (OR)

M/D TOTCO

Chapter 3 Digital Gauge I & IIINSTALLATION Manual 26-102

Figure 3-2. Digital Gauge II Installation - Block Diagram

In order to connect Digital Gauge II to two sensors in different locations, a Junction Box must be used, as shown in Figure 3-3.

Figure 3-3. Digital Gauge II Multi-Sensor Installation - Block Diagram

Table 3-1. Gauge Sensor Cable Part Numbers

Set-up PVC CableP/N

Marine Shipboard Cable P/N

(1) Analog and (1 or 2) Digital Sensors

221015-09XX * 221015-10XX

(2) Digital Sensors 221015-03XX * 221015-04XX

* XX denotes cable length code per cable length chart in Appendix C

DIGITAL - 1INPUT

DIGITAL - 2 INPUT

ANALOGINPUT

EXTERNAL POWER (or)BATTERY

ALARMRELAY

OUTPUT

ANALOGOUTPUT

Sensor #1

Sensor #2

Junction BoxGAUGE SENSOR CABLE SENSOR

CABLE221311-001 (or)221311-002


Digital Gauge I & II Chapter 3Manual 26-102 INSTALLATION

3-2 Mounting Procedures

The Digital Gauge (I & II) can be mounted in two different methods- Box Mount or Panel Mount.

3-2-1 Box Mounting

There are two options available when box mounting the Digital Gauge.

1. Direct mount gauge (with battery pack) to box surface.

2. Bracket mount gauge (external power or battery), then into the box.

Table 3-2. Sensor to J-Box Cable Part Numbers

Set-up P/N Application Construction

Any Sensor 946915-008 * Standard (PVC) 4 twisted shielded pairs

Any Sensor 946915-007 * Marine Shipboard 4 twisted shielded pairs

*Bulk cable part number- connectors not included.

Table 3-3. Junction Box Options

P/N Description Cable Compatible

221311-001 J Box, 18 Terminals, EEx e, 6 Port PVC Cable

221311-002 J Box, 18 Terminals, EEx e, 6 Port Exane

SP102-20001 J Box, 9 Terminals, 3 Port PVC Cable



3-2-1-1 Direct Mount With Attached Battery Pack

If the battery pack is attached, three 1/4 X 20 screws are used to mount the Gauge in the box or the selected bulk head location.

Figure 3-4. Box Mount Screw Locations

Figure 3-5. Box Mount Hole Pattern

3-2-1-2 Mount With Brackets - External Powered or Battery Pack

Whether the Digital Gauge is externally powered or the battery pack is attached, it will be neces-sary to attach an intermediate mounting bracket, P/N 221033-001, P/N 221033-002 or P/N 221033-003, to the back of the Gauge. Brackets 221033-001 and 221033-002 are designed for wall mounting, while the 2210033-003 was designed for flat surface mounting. The P/N 221033-001 bracket has a 15° tilt for those applications requiring tilt. Attach the mounting bracket in the box using three 1/4 X 20 SST screws. Mount the gauge into the bracket using four #8 X 32, 1 inch long screws.

BOX MOUNTMounting Studs

4.90"

4.312"

2.45"

.281 dia.



Figure 3-6. 221033-001 Bracket Assembly





Figure 3-9. 221033-001 and 221033-002 Mounting Dimensions

Figure 3-10. 221033-003 Mounting Dimensions

NOTE

Gauge brackets, 221033-001, 221033-002, and 221033-003 can be usedwith Digital Gauge and attached battery pack or externally powered.



3-2-2 Panel Mounting

The Digital Gauge (I & II) can be panel mounted to accommodate two different configurations.

1. Six-inch bezel design

2. Ten-inch bezel design.

3-2-2-1 Panel Mounting - Six inch Bezel

To panel mount the Digital Gauge with the six-inch bezel, it will be necessary to cut a circular hole (6.375") in the panel. Drill four holes using a 1/4 inch drill bit around the parameter of the hole to match the hole pattern as shown in Figure 3-12. Insert four 10 X 32 screws in the front case ring and continue through the face plate of the console panel. Attach a lock-washer and nut to each of the four screws.

Figure 3-11. Panel Mount Screw Locations (Six-Inch Bezel)

Figure 3-12. Panel Mount Hole Pattern (Six-inch Bezel)

PANEL MOUNTMounting Holes

4.90"

4.90"



3-2-2-2 Panel Mounting - Ten inch Bezel

To panel mount the Digital Gauge with the ten-inch bezel, it will be necessary to cut a circular hole (6.375") in the panel. Drill four holes using a 1/4 inch drill bit around the parameter of the hole to match the hole pattern as shown in Figure 3-14. Insert four 10 X 32 screws in the front case ring and continue through the face plate of the console panel. Attach a lock-washer and nut to each of the four screws.

Figure 3-13. Panel Mount Screw Locations (Ten-inch Bezel)

Figure 3-14. Panel Mount Hole Pattern (10-inch Bezel)

NOTE

The Digital Gauge with the Ten-inch bezel is intended to retrofit "TOTCO"gauges which have a pre-cut 7.37" diameter cut-out (hole) in the panel.

PANEL MOUNTMounting Holes

5.656"

5.656"



3-3 Cable Assemblies

Complete cable assemblies are available from M/D TOTCO in two varieties- standard and marine. See Appendix C for available cables and part numbers. Refer to Table 3-4 to complete the length dash number.

3-4 Power Requirements for Intrinsically Safe Operations

To maintain intrinsic safety, Digital Gauge I and Digital Gauge II must be powered by external power with a safety barrier or via the M/D TOTCO battery pack. If externally powering the gauge, the following two options apply- 1) externally powering the gauge from an unregulated 9-36 VDC or AC (120/240VAC) supply or 2) externally powering the gauge from a regulated 12 Volt input.

Other than external power, the Digital Gauge can be powered by a M/D TOTCO replaceable bat-tery pack and maintain it’s intrinsic safety rating.

CAUTION

Do not exceed 10 IN/LBS of torque on bezel mounting screws. Excessivetorque may result in damage to bezel.

Table 3-4. Cable Length Dash Number Designators

Cable Length Part Number Designators

Dash No.

Length in FT

Dash No.

Length in FT

Dash No.

Length in FT

Dash No.

Length in FT

01 5 11 55 21 150 31 325

02 10 12 60 22 160 32 350

03 15 13 65 23 170 33 375

04 20 14 70 24 180 34 400

05 25 15 75 25 190 35 425

06 30 16 100 26 200 36 450

07 35 17 110 27 225 37 475

08 40 18 120 28 250 38 500

09 45 19 130 29 275 39 550

10 50 20 140 30 300 40 600



3-4-1 Unregulated Power - 9-36VDC or 120/240 VAC

Unregulated DC or AC power must be linked to the Digital Gauge via the M/D TOTCO external Regulator/Barrier Power Box, which accepts unregulated 9-36 VDC or 120/240 VAC. This power source is converted to a stable, regulated +12VDC supply and passed through a current limiting barrier to provide 6.25 VDC to 8.45 VDC when connected to the gauge.

Figure 3-15. External Power (Intrinsically Safe Application)

3-4-2 Regulated 12 Volt Input Power

If regulated 12 Volt input power is available, a Regulator/Barrier assembly is not required. How-ever, it will still be necessary to interface with a Barrier Junction Box. Acceptable barriers are listed in Table 3-5.

Figure 3-16. Regulated 12 Volt Power (Intrinsically Safe Application)

WARNING

Intrinsically safe (I.S.) applications require a barrier assembly between thegauge and power. (Refer to barriers listed in Table 3-5) The barrier containsan internal resistor which provides current limiting, I.S., power to the gauge.Failure to use a barrier assembly could cause severe damage to the gaugeand will impair intrinsic safety.

NOTE

If power to the barrier exceeds 12.5 Volts, an internal barrier fuse will blowrendering the barrier useless and permanently damaged.

9-36 VDC

110/120 VACRegulator/Barrier

Power Box

Digital Gauge

I & III.S. OutputVoltage

P/N 221106-XXX

12

M/D TOTCODigital Gauge

I & III.S. OutputVoltage

PowerSupplyUPS

VACVAC

max Vout = 12.5 V min Vin = 12 V

VDC

CUSTOMER SUPPLIED EQUIPMENT

Barrier/J-Box



Figure 3-17. Regulated 12 Volt Power (I.S. application - No backlighting)

Figure 3-18. Regulated 12 Volt Power (I.S. application - With backlighting)

NOTE

To prevent power interruptions to the gauge, it is strongly recommended thatthe 12 Volt power supply be powered via a Uninteruptable Power Supply (UPS).

Table 3-5. Acceptable Barriers

Manufacturer P/N M/D TOTCO P/N Wiring - No Backlighting

Wiring - With Backlighting

MTL715P H10992A-715P Figure 3-17. Figure 3-17.

MTL765AC H10992A-765A Figure 3-17. Figure 3-18.

MTL767P H10992A-767P Figure 3-17. Figure 3-18.

SB-49140M-1250 951539-002 Figure 3-17. Figure 3-17.



3-4-3 Battery Pack

Digital Gauge I or II may be powered by a replaceable intrinsically safe battery pack. The battery is attached to the back of the Digital Gauge by four SST screws. The connector is recessed into the battery pack face and interconnects with the connector located in the middle of the Digital Gauge back.

Battery Life will vary, dependent upon the application and the type of sensors connected to the Digital Gauge. A breakdown of expected battery life by sensor type is available in Appendix B of this manual.

Figure 3-19. Battery Pack Installation

Table 3-6. Power Cable Assembly Part Numbers

M/D TOTCO Cable Part Numbers

Standard 221039-01XX *

Marine 221039-02XX *

* See Table 3-4 for cable length code

NOTE

Substitution of barriers or improper installation may impair intrinsic safety.

REPLACEABLEBATTERY PACK

DIGITALGAUGE I & II



3-5 Power Requirements for Non-Intrinsically Safe Operations

There are two options for powering the gauge in a non-I.S. application.

1. When using the gauges in a non-intrinsically safe application, a safety barrier is not required. If a 12 volt power supply is used, the Digital Gauge must be wired with a current limit resistor (P/N 911444-151) to prevent damage to the device. Refer to Figure 3-20.

2. If a laboratory, adjustable type supply is available, follow the wiring information in Figure 3-21.

Figure 3-20. Wiring (Option 1)- Non-Intrinsically Safe Operation

WARNING

Substitution of battery pack or it’s components may impair intrinsic safety.

WARNING

Never supply 12 volt power directly to the Digital Gauge without using the49.9 ohm resistor shown in Figure 3-20. Failure to do this can result inpermanent damage to the gauge.

GROUND

12 VOLTS

49.9Ω 3 WATTRESISTOR

B (gnd)

D (+V in)P/N 911444-151

(10-14 V Max)8.1V Typical(6.25V min - 8.45V max)



Figure 3-21. Wiring (Option 2) - Non-Intrinsically Safe Operation

WARNING

When powering a Digital Gauge without a barrier or current limiting resistor(49.9Ω), the operating voltage range must be 6.25VDC (min) to 7.1VDC(max). Exceeding 7.1VDC can cause permanent damage to the gauge.

GROUND

B (gnd)

D (+V in)

6.5V Nominal

LABPOWER SUPPLY

6.75V SUPPLY(6.25V min - 7.1V max)



3-5-1 Connectors

Four interface connectors are located on the backside of the DIgital Gauge. Three are vis-ible with the battery pack installed, the other is located behind the battery pack. Table 3-7 describes each pin by designator and function.

Figure 3-22. Digital Gauge I & II (Backview)

Table 3-7. Connector Designators and Functions

Connector Designator Function

J1 Power Input

J2 Alarm Relay

J3 Sensor Input

J4 Analog Output

T1 Earth Ground

T2 I.S. (barrier) Ground

J1

J2 J3J4T1

T2



NOTE

1. Always connect T1 (earth ground lug) to local ground with a short (2-4 inch) 12 AWG (or larger) wire. This provides an earth ground for theDigital Gauge Case.

2. Always connect the shield wire on Cable 221015-XXXX to local ground directly (not to the T1 lug).

CAUTION

Do not torque T1, T2 lugs more than 4 IN/LBS.

WARNING

When the Digital Gauge is battery powered, do not connect anything toterminal T2. Terminal T2 is only used to connect to an I.S. barrier ground,when the device is powered via an external barrier.

METAL FRONT PANEL

DIGITAL GAUGE

T2

T1

SHIELD WIRE

221015-XXXX



3-5-1-1 Power Input Connector

The power input connector is located on the back of the digital gauge. This four pin connector is used to connect power from the power source to the digital gauge, either battery or external power.

Figure 3-23. Power Input Connector

3-6 Alarm Connection

The Digital Gauge II provides a relay contact output for alarm actuation. Relay contacts are con-nected to pin A and pin B on the J2 connector (Figure 3-24.). When an alarm limit (HIGH or LOW) is reached or exceeded, an internal relay contact is closed allowing external power to the alarm device. Three separate Alarm Device installations are addressed in this manual. In all three instal-lations the Digital Gauge may be either powered by battery or by the external source. However, the Alarm Device (i.e Horn) is always powered via the external barrier assembly.

3-6-1 Digital Gauge & Horn (DIV 1/Zone 0), Barrier (Safe Area)

A typical installation includes Digital Gauge II and Alarm Horn located in the hazardous area (DIV 1/Zone 0) with the Barrier located in the safe area. A certified intrinsically safe Barrier with the safety parameters listed in Table 3-9 must be used. Figure 3-24. illustrates the correct wiring pro-cedure for this application

Table 3-8. Power Input Connector

Pin Designator Function

A + Battery I.S. Power

B Ground

C Not used

D + External Power In

Table 3-9. Barrier Safety Specifications

Barrier Specifications

Voltage Max Output 28V

Current Max Output 93MA

AB

C D



Figure 3-24. Alarm Device Installation

Table 3-10. M/D TOTCO Barrier Part Numbers

Manufacturer # M/D TOTCO P/N

MTL728+ H10992A-728P

MTL708+ H10992A-708P

Table 3-11. Cable Assembly Part Number’s - Alarm Installation





3 1

(I.S.)1 2

P/N 220451-001

24

HORN



3-6-2 Digital Gauge (DIV 1/Zone 0) & Horn/Barrier (DIV 2/Zone 2)

An alternative installation includes the Digital Gauge located in a "DIV 1/Zone 0" location and the Alarm Horn and Safety Barrier located in a "DIV 2/Zone 2" area. A M/D TOTCO Alarm/Barrier assembly, P/N 231125-103 or 231125-105, is required for this application. Figure 3-25. illustrates the correct wiring procedure.

Figure 3-25. Alarm Device Installation

3-6-3 Digital Gauge (DIV 1/Zone 0) & Barrier and Horn (Safe Area)

An alternative installation includes the Digital Gauge located in a "DIV 1/Zone 0" location and the Alarm Horn and Safety Barrier located in a safe area. A M/D TOTCO Alarm/Barrier assembly, P/N H10992A-7875P, and a customer supplied horn is required for this application. Figure 3-26. illustrates the correct wiring procedure.

Figure 3-26. Alarm Device Installation (Div 1/Zone 0 and Safe Area Combination)

P/N 231125-103 (or) -105

0

A C

KEYBOARD CONNECTOR

SAFE AREA HORNCUSTOMER SUPPLIED

P/N H10992A-787SP

12

34



3-6-4 Digital Gauge & Horn (Safe Area)

In a safe area (non-IS) location, the Digital Gauge (I & II) can be connected to an alarm device without the use of a barrier assembly. However, this installation requires an appropriate sized resistor be placed in series with the gauge and alarm device. This ensures the maximum switch current is not exceeded. Refer to Table 3-12 to determine resistor sizing.

.

Figure 3-27. Alarm Device Installation (Safe Area)

3-7 Serial Communication - RS485 Link (Digital II Only)

The Digital Gauge (II) has a serial communication link which may be used to communicate between Digital Gauges or other safe area devices.

Up to ten Digital Gauge II’s can be linked via the serial interface link. In this application, one device will be the Sender (Master) unit and the other devices are Receivers (slaves). The Receiver oper-ates independent of the Sender device, and may display any configured channel. Additionally, independent alarms can be set at the slave unit.

Table 3-12. Relay Contact Specifications

Maximum Switched Voltage MAX Switched I

0 - 10 Volts 100 mA

10 - 20 Volts 75 mA

20 - 30 Volts 50 mA

POWER SUPPLY VOLTAGE - HORN VOLTAGE REQUIRED

MAX SWITCHED I (SEE TABLE 3-12)R =



3-7-1 Gauge to Gauge in Hazardous Areas (Digital Gauge II)

When linking one Digital Gauge II to another Digital Gauge II the following wiring instructions should be followed. Refer to Chapter 4, section 4-6-5 for set-up information.

1. Connect Pin F (RS485+) on Sender unit to Pin F on Receiver unit(s).

2. Connect Pin E (RS485-) on Sender unit to Pin E on Receiver unit(s).

3. Connect Pin U circuit ground on Sender unit to Pin U on all Receiver unit(s).

Figure 3-28. Sender/Receiver (Hazardous Location) Installation

NOTE

Reference drawing 221329-001 for quick set-up and calibration instructionsfor a master/slave gauge system. (See Appendix E)

Reference drawings 221389, 221390, 221391, 221392, and 221393 forMaster/Slave junction box wiring configuration options. (See Appendix E)


Figure 3-29. Generic Wiring Diagram for 221311-XXX J Box

NOTE

Cable must be twisted, individually shielded pairs, with RS485+ andRS485- as one twisted pair and Ground in the second twisted pair.

NOTE

On all receivers, do not connect anything to the barrier (circuit) ground lug(T2). All Receiver gauges are linked and dependent on the Master gaugeground. If battery powered, connect barrier ground (T2) on the Mastergauge to local ground. If externally powered through a barrier, ensure T2is connected to barrier ground at the barrier box.

CAUTION

Never connect barrier ground (T2) on Receivers to local ground. Highground current could occur.

NOTE

Reference drawings 221389 through 221393 for exact Master/Slave J-Boxwiring. (See Appendix E)



3-7-2 Gauge in Hazardous Area to Gauge in Safe Area Installation

A Digital Gauge II located in a hazardous area can be linked to a Digital Gauge II located in a safe area. In this application, like the Digital Gauge to Digital Gauge application, one device will be the Sender (master) device and the other unit operates as the Receiver (slave) device. A safety bar-rier, MTL755, must be installed between the Digital Gauge in the hazardous area and the Digital Gauge in the safe area. Refer to Figure 3-29. for wiring information.

Figure 3-30. Hazardous to Safe Area Gauge Installation

Follow the steps below when wiring a digital gauge in a safe area to a digital gauge in a hazardous location.

1. Connect pin F to pin F.

2. Connect pin E to pin E.

3. Connect pin U to barrier ground.

NOTE

A barrier is not required if safe area gauge is powered via an I.S. batterypack or I.S. barrier.



3-8 Sensor Wiring Procedures

Digital Gauge I or II may be installed in numerous applications. The application will determine what type of sensor is required - Analog or Digital. The Analog sensors can be divided into the following four groups:

• M/D TOTCO designed sensors (Pressure Transducers, Tong Torque, etc)

• Strain gauge sensors (1.8 mV/v to 2.1 mV/v)

• 0-5 Volt sensors (Pit probes, Mud Flow, etc)

• 4-20 mA sensors (isolated and externally powered)

The Digital sensors can be divided in three groups:

• Proximity sensors (70 Hertz, 1000 Hertz)

• Limit switch sensor

• Customer supplied (safe area) digital input to gauge

The Digital Gauge (I & II) may be interfaced with a M/D TOTCO DAQ device. Specific wiring infor-mation is available within this chapter.



3-8-1 Analog Sensor - Pressure Transducer Installation

The Digital Gauge (I & II) can be installed to a M/D TOTCO pressure transducer to monitor various pressure applications. Two pressure transducer capacities are available from M/D TOTCO. The operator must select the proper sensor, dependent upon the pressure associated with the specific application. The wiring procedure remains constant for both capacities.

Figure 3-31. Pressure Transducer Installation

Table 3-13. M/D TOTCO Pressure Transducer P/N’s

M/D TOTCO P/N Capacity Notes

221042-001 5000 PSI Transducer w/ 1502 Weco Union



Table 3-14. Cable Assembly Part Numbers - Pressure Application




* See Table 3-4 for cable length code.

WARNING

Verify that the selected pressure transducer’s capacity meets or exceedsthe maximum capacity of the application. Using the wrong pressuretransducer can lead to serious injury or death.



When connecting to a M/D TOTCO pressure transducer sensor, follow the below steps:

1. Wire cable assembly as shown in Figure 3-32.

2. Trim and remove outside jacket approximately 5 inches.

3. Laterally cut outside shield braid to 5 inch jacket trim mark.

4. Twist braided shield together.

5. Cover twisted braid with heat shrink material and shrink.

6. Attach eyelet to end of twisted shield.

7. Connect eyelet to case lug on back of gauge (T1).

Figure 3-32. Wiring Diagram - Pressure Transducer

NOTE

Reference Digital Gauge catalog drawing 221035 for Pressure Sensoraccessories (wingnut, sub assembly, etc.).

NOTE

Cable must be constructed of (4) twisted pairs of 20-AWG individuallyshielded wire and jacketed with an overall shield. TO MAXIMIZEACCURACY - Minimize cable length



3-8-2 Analog Sensor - Strain Gauge Bridge Installation

The Digital Gauge (I &II) can be connected to a variety of strain gauge sensors. The battery oper-ated gauge is capable of running any strain gauge with a 2mv/V output with a bridge resistance of between 3.5K ohm and 10K ohm. The range must be between 1.8mv/V (minimum) and 2.1mv/V (maximum). The externally powered Digital Gauge (I & II) can power any strain gauge bridge (1.8mv/V - 2.1mv/V) with a bridge resistance of 350 ohms to 10K ohms.

These sensors can be used in various applications to monitor a variety of parameters. Typical application include- (Line tension, Anchor Tension, Tong Torque, and Bulk Weight)

Figure 3-33. Strain Gauge Application - Tension Load Cell

The wiring procedure remains constant for all cases. Figure 3-34. illustrates the procedure for wir-ing to a strain gauge sensor to a Digital Gauge.

NOTE

Connect the CABLE CONNECTED line to GROUND (Pin F) at the pressuretransducer connector cable end. This loop will enable the digital gauge todisplay cable error messages if the cable becomes damaged or thePressure Sensor is disconnected.

NOTE

The output of a strain gauge device is a very low level signal (mv/volt). Inorder to maximize accuracy - minimize cable length. Maximumrecommended cable length is 25 feet.



The RCAL (Automatic Calibration) value will vary dependent upon the bridge resistance value and mv/V output. Table 3-15 lists the various bridge resistance values versus the required RCAL resis-tor value.

NOTE

The RCAL resistor is required if auto calibration is preferable or if a knownload (weight) is not available for the calibration procedure. RCAL simulatesa near full scale load to the gauge and is automatically activated duringcalibration, if you have wired the sensor using the RCAL connections.

Table 3-15. Strain Gauge Ohm Resistance and RCAL value

ExternalJ Box RCAL

ResistorPart Number

Description/Information

48.63K 4730-48623 Typical 350 OHM Bridge, 2 MV/V (Stand 50K -1.37K=48.63K)

73.63K 4730-73623 Typical 350 OHM Bridge, 1.5 MV/V (Stand 75K -1.37K=73.63K)

98.63K 4730-98623 Typical 350 OHM Bridge, 1MV/V (Stand 100K -1.37K=98.63K)Typical 700 OHM Bridge, 2 MV/V (Stand 100K -1.37K=48.63K)




1 MEG 4720-10045 Typical 5000OHM Bridge, 1.5 MV/V (Stand 1MEG -1.37K=INSIGF)

Connect (2)748.63K To

Obtain 1.5MEG

Use (2) 4730-74833

Typical 5000 OHM Bridge, 1 MV/V (Stand 1.5MEG -1.37K=INSIGF)

Note: All RCAL values are .1%, 10 PPM resistors.

NOTE

Contact M/D TOTCO factory for RCAL values if your strain gauge sensoris not a 2mv/V device.



When connecting to a strain gauge (5K to 10K ohm) transducer sensor, follow the steps below:


2. Install RCAL resistor in Junction Box TB1-2 to TB1-3.

3. Install a jumper from Junction Box TB1-5 to TB1-7.

4. Install a jumper from Junction Box TB1-4 to TB1-7.

5. Connect (+) signal to Junction Box TB1-1.

6. Connect (-) signal to Junction Box TB1-2.

7. Connect (+) excitation to Junction Box TB1-6.

8. Connect (-) excitation (Ground) to Junction Box TB1-7.

Figure 3-34. Wiring Diagram - Bridge Installation

Table 3-16. Cable Assembly Part Numbers - Pressure Application





NOTE

If you have the ability to apply a known load (near full capacity) to the straingauge sensor and you prefer not to use the RCAL feature, do not installthe external RCAL depicted in Figure 3-34.




NOTE

Cable must be constructed of (4) twisted pairs of 20-AWG individuallyshielded wire and jacketed with an overall shield. The shield must beconnected to a local earth ground.

NOTE

TO MAXIMIZE ACCURACY - Minimize cable length.

NOTE

Reference Strain Gauge Calibration Procedure 221370 for detailedinstructions on calibrating a Digital Gauge with a strain gauge sensor.

NOTE

If this application is for Tong Torque, refer to Calibration Procedure 221416and 221370.


3-8-3 Analog Sensor 0-5 Volt Potentiometer (3-wire) Installation

The Digital Gauge (I & II) can be installed with a variety of 0 - 5 Volt sensors. These sensors can be used in various applications to monitor a variety of parameters. The following channels typically utilize a 0-5 Volt sensor- (Pit Level, Mud Flow, and Trip Tank).

The following two sections describe the installation procedures for Pit Level applications.

Figure 3-35. Pit Probe Installation



3-8-3-1 Pit Probe Wiring (P/N 262622-Series)

When connecting the Digital Gauge to a Pit Probe assembly (P/N 262622-Series), follow the below steps:

1. Refer to Figure 3-36. (Wiring Diagram - Pit Probe).

2. Join Signal (-) and VREF from gauge together and connect to TB1-4.

3. Connect Cable Connected to TB-2 (black).

4. Insert resistor (R1),1K Ohm at 1/8 Watt, between J3-C and TB-1. (See Note)

5. Connect 5V (+) from gauge to R1 resistor.

6. Connect Signal (+) from gauge to TB1-3 (white).

Figure 3-36. Wiring Diagram - Pit Probe (P/N 262622-Series)

NOTE

When using Pit Probes P/N 262622-205 (6 ft.), 262622-202 (8 ft.), or262622-201 (10 ft.), with a battery operated Digital Gauge, you must inserta 1K Ohm (5% - 1/8w) resistor P/N 911440-010 inside the Pit Probe J-Boxas illustrated. This resistor prevents excessive battery current drain on thebattery. Failure to insert resistor will significantly shorten battery life.

NOTE

Cable must be constructed of (3) twisted pairs of 20-AWG individuallyshielded wire and jacketed with an overall shield. Cable is available fromM/D TOTCO in two varieties - standard and marine. The part number forstandard cable is 221015-05XX, with the XX determine the length. The partnumber for marine cable is 221015-06XX, with the XX determining thelength. Refer to Table 3-4 to complete the length dash number.



3-8-3-2 Pit Probe Wiring (P/N H10941A-Series)

When connecting the Digital Gauge to a Pit Probe assembly (P/N H10941A-Series), follow the steps below:

1. Refer to Figure 3-37. (Wiring Diagram - Pit Probe)

2. Join Signal (-) and VREF lines together.

3. Connect Signal (+) from gauge to TB1-2 (brown).

4. Join CABLE CONNECTED and GROUND together and connect to TB1-3 (white).

5. Connect 5V (+) from gauge to TB1-1 (black)

Figure 3-37. Wiring Diagram - Pit Probe (P/N H10941A-XX)

3-8-3-3 Pit Probe Installation

Ensure that mud probes selected for each installation are the correct length. If mud probes do not already have floats in place, loosen set screws in each retaining collar and remove collars form end of each probe. Place a float on each probe and replace the collars. Align the top of the retain-ing collar to one of the lines etched around the lower part of each probe. The line nearest the bot-tom of the probe is used with an eight inch spherical float. The upper line is used with a twenty inch disk float. Install the mud probe/s as follows:

1. Install mud probes in areas with a minimum of mud turbulence. Tighten mounting clamp on tank edge or on cross member over tank.

2. Adjust extension bracket over tank. Place probe assembly in tank and hold in ver-tical position. Before attaching, move probe assembly in a circular pattern to ensure nothing hampers float movement as mud level changes.

3. Place probe in clamp, then tighten clamp bolts.

4. Run cables and connect to Digital Gauge (I &II) as shown in Figure 3-36. or Figure 3-37., dependent upon which probe will be used. Wrap cables along run for neatness and reduce possibility of cable damage.

5. Recheck all electrical connections for security and ensure that installation does not interfere with normal rig operations.



3-8-3-4 Flow Sensor Application

Digital Gauge (I & II) can be configured as a Flow Meter when installed with a M/D TOTCO flow sensor (P/N 270701-103).

Figure 3-38. Flow Sensor Installation

3-8-3-5 Flow Sensor Preliminary Checks and Adjustments

Certain preliminary checks and adjustments should be made prior to installing the sensor. It is recommended that the following steps be taken:

1. Remove the mud flow sensor transmitter top cover. Disconnect and remove the signal cable.

2. With sensor paddle in “no-flow” position, measure for 1.4K ohms to 1.5K ohms across transmitter terminals 1 and 2.

3. Move paddle to "full-flow" position. Resistance should increase to approximately 4K ohms.

4. If resistance does not start at minimum reading with paddle in "no-flow" position, or increase linearly when paddle is moved slowly to "full-flow" position, then per-form entire procedure that follows this step. If resistance increases linearly, but "no-flow" is out of tolerance, adjust electrical element as described in Steps 8 and 9. If correct resistance values cannot be obtained, check for faulty electrical and mechanical components, including 5K ohm potentiometer, 1K ohm fixed resistor, or some part of linkage assembly between paddle and potentiometer shaft.

5. Disconnect three wires connecting potentiometer to terminal strip.

6. Ensure that 1K ohm resistor is connected between terminals 2 and 4.

7. Using digital multi-meter, locate two potentiometer wires that read approximately 5K ohms across both. Move paddle from position "A" and "B". If correct wires are selected, 5K ohm reading will remain constant.



8. Connect one wire located during Step 7 to terminal 1 of sensor terminal strip. Con-nect other wire to terminal 3. Connect remaining wire to terminal 4. This wire is from movable center arm of potentiometer.

9. Loosen bell crank set screw. With sensor paddle in position “A”, adjust potentiom-eter shaft for reading of 2.5K ohms across terminals 1 and 2. Tighten set screw. This sets potentiometer for an initial mid-range reading and determine if wires connected to terminals 1 and 3 need reversing.

10. Connect digital resistance meter to terminal 1 and 2. When paddle is raised from position "A" toward "B", meter reading should increase. If reading decreases, position of wires connected to terminals 1 and 3 need to be reversed. If so, and wires are reversed, repeat this step.

11. After completing above steps, flow sensor should be properly wired and adjusted. Proceed to next paragraph for sensor and signal cable installation.

3-8-3-6 Flow Sensor Wiring

When connecting the Digital Gauge to a Flow Sensor assembly (P/N 270701-103), follow the steps below.

1. Refer to Figure 3-39. (Wiring Diagram - Flow Sensor).

2. Join Signal (-) and VREF lines together.

3. Connect Signal (+) from gauge to TB1-2.

4. Join CABLE CONNECTED and GROUND together and connect to TB1-1 (green).

5. Connect 5V (+) from gauge to TB1-3 (black).

.

Table 3-17. Cable Assembly Part Numbers - Flow Sensor Application







Figure 3-39. Wiring Diagram - Flow Sensor (P/N 270701-103)

3-8-3-7 Flow Sensor Installation

Since the mud flow sensor is installed on the flow line with the paddle protruding into the mud flow, a hole must be cut in the flow line and the sensor base must be welded to the flow line. If a base is already mounted to the flow line form a previous rig-up, it can be used. If no base is mounted, request a welder to install one. Locate mud flow sensor in a section with some downward slope toward the shafer pit and where it can be accessed for service. After the base is welded to the mud flow line, install the mud flow sensor as follows:

1. Adjust paddle to within 1/4 inch of bottom of flow line, but not touching when in down position. Bolt mud sensor to base.

2. Run cables and connect mud flow channel as shown in Figure 3-39. Tie wrap cables along run for neatness and to reduce possibility of cable damage.

3. Recheck all electrical and mechanical connections for security and ensure that installation does not interfere with normal rig operations.



Figure 3-40. Mud Flow Sensor Components

3-8-4 4-20mA Sensor (Customer Supplied)

Digital Gauge (I & II) can be connected to any safe area (customer supplied) 4-20mA sensor by following the wiring diagram Figure 3-41.

Figure 3-41. 4-20mA Wiring Diagram (I.S. application)



Figure 3-42. 4-20mA Wiring Diagram (Non-IS Application)

NOTE

Connect Pin K and Pin L together at Pin 4 of barrier assembly, or connectdirectly together in J3 gauge connector.

NOTE

For Non-IS applications, connect the output of the 4-20mA repeater directlyto the Digital Gauge.



3-8-5 Hookload/Line Tension Transducer Sensor - (4-20mA)

The Digital Gauge (I & II) can be connected to a M/D TOTCO SC103 based sensor as diagramed in Figure 3-43.

Figure 3-43. Wiring Diagram - Hookload/Line Tension Transducer

NOTE

Connect Pin K and Pin L together at Pin 4 of barrier assembly, or connectdirectly together in J3 gauge connector.



3-8-6 Hookload/Line Tension Transducer Sensor Powered by Adjustable 24 V Supply

The Digital Gauge (I & II) can be connected to a M/D TOTCO SC103 based sensor as diagramed in Figure 3-44. If an adjustable 24V (set to 25.5V) power supply is used, the 4-20mA Repeater is not required.

Figure 3-44. Hookload/Line Tension Sensor Powered an Adjustable Power Supply

WARNING

Do not exceed 26V to the safe barrier shown in Figure 3-44. Exceeding the26V will cause the internal safety barrier fuse to blow.

NOTE

The barriers specified in Figure 3-44. have replaceable fuse modules andare din rail mountable.



CH

AN

NE

LC

HA

NN

EL

MountPanel

PanelMountScrew

ShorWirePane

3-8-7 Digital Gauge Connected to a 4-20mA Sensor via a UL DAQ

The Digital Gauge (I & II) can be connected to a M/D TOTCO SC103 based 4-20mA sensor and a M/D TOTCO U.L. DAQ as shown in Figure 3-45. Refer to installation and control drawing 219569.

Figure 3-45. Digital Gauge Connected to a 4-20mA Sensor via a U.L. DAQ

CAUTION

Do not connect any shield wires to the DAQ shield or signal ground. Tie allshields together in a J-Box and provide a single point ground using theshield wire on cable. Shield wire for 221015-08XX should be grounded onthe gauge mounting plate only. Refer to Figure 3-45.

B D

KLAJ3

J1

CA

4-20mASensor

AN

ALO

G

SOURCE

SIG IN

GND

DIG

ITA

L

POWER+GND+10V

GND

+24

J-BOXP/N 221311-002

UL DAQ

P/N 221039-02XX

CABLE P/N 221015-08XX


B

EARTHGROUND

PN 221452-001(40 Ω) Resistor

GreenShield Wire

J3

ing

ings

t Tol

J1

CABLE

U

From Sensor Cable

PWR +

PWR -

(6V - 10V)

Sig +

Sig -

GND

4-20mAJumper

Cable Connected



AN

ALO

GC

HA

NN

EL

DIG

ITA

LC

HA

NN

EL

SS

MountPanel

PanelMountScrew

ShorWirePane

r

.)

3-8-8 Digital Gauge Connected to a 4-20mA Sensor via a Barrierless DAQ (Non U.L.)

The Digital Gauge (I & II) can be connected to an M/D TOTCO 4-20mA (SC103) sensor and barri-erless DAQ as shown in Figure 3-46.

Figure 3-46. Digital Gauge Powered by 4-20mA Sensor via a Barrierless DAQ

NOTE

A maximum of 11 Digital Gauges may be powered from the digital 10Vsource on a U.L. DAQ. Only digital source channels 1-4, 7-10, and 12-14are able to power the Digital Gauge.

B D

KLAJ3

J1

CA

4-20mASensor

SOURCE

SIG IN

GND

POWER+GND+12V

GND

+25

BARRIER BARRIERLE

P/N 221039-02XX



B

EARTHGROUND

GreenShield Wire

J3

ing

ings

t Tol

J1

CABLE

U

From Sensor Cable

PWR +

PWR -

DAQBOX

34

1278

7SP

3 1

710P

+

3 1

710P

+

3 1

Cro

use

Hin

ds

(P/N H10992A-787SP MTL 787SP)

(P/N H10992A-710PP MTL 710PP)

951539-002(SB-49140M-1250)

Sig +

Sig -

GND

4-20mAJumper

Cable Connected

GND

Power 1

J1P-J6PPower Barrie

(NON U.L

(SC103)

(P/N 950864-006 MTL 7187SP)

(P/N 950864-009 MTL 7162+)

-OR-

-OR-



3-8-9 Digital Input - Proximity Sensor (Low Frequency Applications- 70 Hertz)

The Digital Gauge (I & II) can be connected to a proximity sensor to measure activities such as pump strokes. Refer to Table 3-19 for listing of acceptable M/D TOTCO proximity sensors. The proximity sensors can be installed to the DIG 1 and/or the DIG 2 input channel on Digital Gauge II. On Digital Gauge I only one digital channel can be used at a time. The operator must select where he prefers this data to be displayed.

Figure 3-47. Proximity Switch Installation

NOTE

Tie Barrier Box shield wires, shown in Figure 3-46, to IS Safety Ground inBarrier Box. Shield wires for the 221015 cable should be earth groundedto metal mounting plate on gauge side only.

A maximum of 3 Digital Gauges may be connected to the BarrierlessDAQ power outputs, J1P - J6P. (Maximum output of DAQ outputs is 12V,240mA)



When connecting the Digital Gauge to a Proximity sensor, follow the steps below:

PREPARATION STEPS

1. Refer to Figure 3-48. (Wiring Diagram)

2. Add jumper from TB1-5 to TB1-7. (Broken Cable Detection)

PROXIMITY SENSOR #1

3. Install (+) brown lead from sensor #1 into TB1-2.

4. Add jumper from TB1-2 to TB1-3.

5. Install (-) blue lead from sensor #1 into TB1-4.

PROXIMITY SENSOR #2

6. Install a jumper in the Junction box from TB1-1 to TB1-6.



Figure 3-48. Wiring Diagram - Proximity Sensor (Low Frequency 70 Hertz)

NOTE

Cable must be constructed of (4) twisted pairs of 20-AWG individuallyshielded wire and jacketed with an overall shield.



3-8-9-1 Digital Input - Proximity Sensor (High Frequency Application - 1000 Hertz)

The Digital Gauge (I & II) can be connected to a proximity sensor with a high frequency output. See Table 3-19 for a list of acceptable M/D TOTCO proximity sensors. The DIG 1 input channel on the Digital Gauge provides a high frequency (1K Hertz) proximity sensor interface for both Digital Gauge I and Digital Gauge II. This input is useful for high frequency applications such as TON MILE, where you have an extremely fast moving target. This input will detect a target that provides a minimum pulse duration of one milli-second.

When connecting the Digital Gauge to a proximity sensor, follow the steps below:

PREPARATION STEPS

1. Refer to Figure 3-49. (Wiring Diagram)

2. Add jumper from TB1-5 to TB1-7. (Broken Cable Detection).

PROXIMITY SENSOR #1





PROXIMITY SENSOR #2

7. Install a jumper in the Junction box from TB1-1 to TB1-6.



Table 3-18. Cable Assembly Part Numbers for Proximity Application




* See Table 3-4 for cable length XX code

Table 3-19. Acceptable Proximity Sensors

M/D TOTCO P/N Description

932814-005 10mm Sense Distance(Proximity only)

H11094A-01 40mm Sense Distance

232389 10mm Sense Distance (Full Assembly)



Figure 3-49. Wiring Diagram - Proximity Sensor (High Frequency 1000 Hertz)

NOTE

Digital channel #1 provides a 1K HERTZ max high frequency inputcapability when wired as shown in Figure 3-49. Digital Channel #2 is onlya low frequency 70 HERTZ max input channel.

NOTE

Cable must be constructed of (4) twisted pairs of 20-AWG individuallyshielded wire and jacketed with an overall shield.

Table 3-20. Cable Assembly P/N’s for Proximity Sensor Installation







3-8-9-2 Limit Switch

The Digital Gauge (I & II) can be installed to any type of switch, such as a M/D TOTCO, P/N 270641, limit switch.

Figure 3-50. Limit Switch Installation

When connecting the Digital Gauge to a limit switch sensor, follow the steps below:

1. Refer to Figure 3-51. (Wiring Diagram - Limit Switch).

2. Add jumper from TB1-3 to TB1-5 (Broken Cable Detection).

SWITCH # 1 WIRING

3. Connect N.O. lead from switch #1 to TB1-1.

4. Connect first common lead from switch #1 to TB1-2.

SWITCH # 2 WIRING

5. Connect second common lead from switch #2 to TB1-3.

6. Connect the N.O. lead from switch #2 to TB1-4.

Figure 3-51. Wiring Diagram - Limit Switch Installation



3-8-10 Digital Gauge To DAQ Installation (UL DAQ)

The Digital Gauge (I & II) is compatible with a M/D TOTCO standard DAQ device.

Figure 3-52. DAQ Installation (UL Certified DAQ)

When connecting the Digital Gauge to a M/D TOTCO standard DAQ device, follow the steps below:


2. Install jumper from TB1-2 to TB1-4.

3. Install jumper from TB1-3 to TB1-6.

4. Connect digital signal output from DAQ to TB1-1.

5. Connect ground from TB1-6 to ground terminal in DAQ.

NOTE

Cable must be constructed of twisted pairs of 20-AWG individually shieldedwire and jacketed with an overall shield.

Table 3-21. Cable Assembly P/N’s for LImit Switch Installation







Figure 3-53. Wiring Diagram - DAQ to Digital Gauge Installation

Table 3-22. Cable Assembly P/N’s for DAQ Installation





NOTE

The DAQ digital output must be calibrated as an inverted analog outchannel.

NOTE

For battery powered gauges, use a.125W, 1%, 5K Ohm resistor, (P/N 911440-037). For externally powered gauges without backlight , usea .25W, 1%, 150 Ohm resistor (P/N 911435-037). For externally poweredgauges with backlight , use a .125W, 1%, 1K Ohm resistor (P/N 911440-010).

NOTE

Figure 3-53. provides up to 65 mA, adequate power for one gauge withbacklighting.



3-8-11 Digital Gauge Connected to Barrierless (Non U.L.) DAQ with Digital Output

Figure 3-54. Digital Gauge Connected to Barrierless (Non-U.L.) DAQ

CAUTION

Do Not connect any shield wires to the DAQ shield or signal ground. Tieshields together in J-Box (as shown in Figure 3-53.). Connect shield wirefrom cable 221015-06XX directly to a local ground on gauge side only,

Table 3-23. Power Cable Assemblies - DAQ to Digital Gauge







3-9 Non-Isolated Digital Connection (Safe Area)

The Digital Gauge (I & II) can be connected to a customer supplied digital input, such as a switch or open collector output. In this application all components must be located in a safe area.The Dig-ital Gauge may be externally powered or battery powered and wiring details are dependent upon the type of power input- see Figure 3-53. and Figure 3-54.

3-9-1 Non-Isolated Digital Connection - External Power

When connecting a customer supplied digital input, such as a switch or open collector output, in a safe area to an externally powered Digital Gauge, follow the wiring diagram in Figure 3-55.

NOTE

- * R1 is 0 Ohms (Jumper TB1-5 to TB1-1 for an externally powered gauge.(As shown in Figure 3-54.)

- * R1 is a 5K Ohm, .125W, 1.0% Resistor (P/N 911440-037) when usinga battery operating gauge.

CAUTION

A maximum of 3 Digital Gauges may be powered form the barrierless DAQJ1P - J6P Power Output (+12V). (Each gauge will draw approximately 85 mA X 3 = 253 mA = Maximum I Draw from +12V Barrierless DAQregulator - no heat sink)



Figure 3-55. Wiring Diagram - Non-Isolated Connection (Externally Powered)

3-9-2 Non-Isolated Digital Connection - Battery Powered

When connecting a customer supplied digital input to a battery powered gauge, follow the wiring diagram in Figure 3-56.

Figure 3-56. Wiring Diagram - Non-Isolated Connection (Battery Powered)

NOTE

For externally powered operation, connect Pin S to Pin H at Barrier Pin 3.



3-10 Isolated Digital Connection (Safe Area) - Battery or External Pwr

Interfacing a Digital Gauge (I & II) with an isolated, safe area signal is accomplished with the use of an opto isolator (shown below). For isolating a safe area digital input to the Digital Gauge, follow the wiring diagram in Figure 3-57.

Figure 3-57. Wiring Diagram - Isolated Connection

NOTE

Digital input requirement are as follows:

Input Frequency: ≤ 60 Hertz

Voltage High Trip Point: 4.2 V

Voltage Low Trip Point: 3.8 V

NOTE

The wiring diagram in Figure 3-57. applied to Digital Gauges which arebattery powered or externally powered.



3-11 Analog Outputs (Digital Gauge II only)

Digital Gauge II has two analog outputs- 0-4.5 volt output and 4-20mA output. The 4-20mA output must be externally sourced and isolated. Both outputs can be used to drive devices such as chart recorders, etc.

A safety barrier must be installed between the gauge and the external device, in order to maintain the gauge’s intrinsic safety. See Figure 3-58., Figure 3-59., and Figure 3-60. for installation wiring details.

Figure 3-58. Wiring Diagram -Analog 0-4.5 Volt Output

Table 3-24. Analog Output (0-4.5V) Cable Assembly P/N’s





NOTE

To maximize accuracy- minimize cable length to ensure gauge and safearea hardware have no ground potential difference.



Digital Gauge II requires an externally sourced (and isolated) power supply be connected to the gauge’s 4-20mA output for proper operation. Refer to Figure 3-59. for typical installation wiringdiagram.

Figure 3-59. Wiring Diagram - Analog 4-20mA Output

Table 3-25. Analog Output (4-20mA) Cable Assembly P/N’s







3-11-1 4-20mA Output Connection (Non I.S.)

When the application calls for connecting the 4-20mA output of a battery operated gauge to a device in a non-intrinsically safe location, the following wiring diagram applies.

Figure 3-60. 4-20mA Output Connection (Non-I.S.)

TABLE 1

NOTE

A 330 Ohm resistor (P/N 911444-300) must be inserted into cable asshown in Figure 3-60. Failure to do so will result in severe damage to gauge.

NOTE

Gauge must be battery powered. Gauge ground (T2) must not be tied torig ground at any point.

B

A

4-20mA (+)

4-20mA (-)

GAUGE CONNECTORJ4 RESISTOR - 330Ω

3 WATT, 5%

CUSTOMERLOAD RESISTOR≤500 Ω

+24V

Battery Operated Gauge (ONLY)


CHAPTER 4OPERATIONS

4-1 Overview

Digital Gauge (I) is capable of processing one analog or one digital channel. Only one of these input signals can be displayed at any one given time. Section 4-2, describes the procedure for set-ting-up an Analog channel. Section 4-3, describes the procedure for setting-up a Digital Channel.

Set-up for Digital Gauge (I) is composed of two basic steps:

1. Channel name configuration

2. Sensor calibration

Digital Gauge(II) is capable of processing one analog and two digital channels. Only one of these input signals can be displayed at any one given time. To view the other two active channels, the operator must press the up arrow (↑) or the (↓) keys. The operator may elect to disable one or two of the available input channels. Section 4-2, describes the procedure for setting-up an Analog channel. Section 4-3, describes the procedure for setting-up a Digital channel.

Set-up is composed of three basic steps:

1. Channel name configuration

2. Sensor calibration

3. Alarm setting - High and Low

NOTE

The section 4-5-1 (Alarm Setting-High/Low) only applies to DIgital Gauge (II)and should be ignored if you are calibrating a Digital Gauge (I).


Chapter 4 Digital Gauge I & IIOPERATIONS Manual 26-102

4-1-1 Front Panel Screen

Figure 4-1. Digital Gauge I & II - Front View (SEE NOTE)

NOTE

Digital Gauge (I) does not contain alarm features. The alarm symbol willbe displayed momentarily after turning on the gauge, but is never active.

ActiveViewingScreen

OperatorKeypad


Digital Gauge I & II Chapter 4Manual 26-102 OPERATIONS

4-1-2 Active Viewing Screen

The Active Viewing Screen is composed of three primary information windows.

• Alpha Display Window

• Numeric Display Window

• Bar Graph Indicator

The Alpha Display Window displays alpha characters, such as PRESS, ALMHI, or CAL A, which are used to guide the operator through the menu structure of the Digital Gauge. The Numeric Dis-play Window displays the active sensor output value in operation mode, or set-up data in calibra-tion and alarm setting modes.

The Bar Graph Indicator is a multi-purpose analog indicator which can be used to view full range of the sensor (zero to full scale) or a specific area within the full range. The lower limit of the range is displayed above and left of the bar graph. The upper limit of the range is displayed above and right of the bar graph. Because these values are limited to three digits, an incremental multiplier is displayed to the right of the bar graph. If (X 100) is displayed, the lower and upper limits of the bar graph should be multiplied by 100.

The Active Viewing Screen contains three notification lighted symbols.

• Battery

• Alarm - High/Low (Digital Gauge (II) - only)

• Trend - Rising/Falling

The Battery notification light (depicted as a picture of a battery) will illuminate, when approximately 90 percent of the batteries power has been expended. It will remain illuminated until the battery is replaced, or total power is lost.

On Digital Gauge (II), the Alarm light (depicted as a bell) will illuminate when a programmed alarm set-point has been reached or exceeded. The set-point may be either a low or high limit value. If a High Alarm is activated, the bell symbol and the UP arrow will light. If a Low Alarm is activated, the bell symbol will light, along with the DOWN arrow.

The Trend enunciator is represented as two symbols- an Up arrow or a Down arrow. If recent sensor input has been increasing, the UP arrow will be displayed, if recent sensor input has been declining, the DOWN arrow will be displayed.

Figure 4-2. Active Viewing Screen

NUMERICDISPLAYWINDOW

ALPHADISPLAYWINDOW

BAR GRAPHINDICATOR

BATTERY

TREND

ALARM



4-1-3 Keypad

The Digital Gauge (I & II) keypad is composed of five function keys.

• The MODE key acts as an ESC (escape) or back-up key. This key will be

used after steps are completed, and the procedure requires returning to a previous

screen.

• The up arrow and down arrow keys are used to scroll through menu

selections, and increase or decrease numeric values.

• The ACK key acts as an enter key. By pressing the ACK key, numeric

values are acknowledged or the device is instructed to proceed forward.

• The ON/OFF key powers the device on or off.

Figure 4-3. Operator Keypad

NOTE

The operator must press the ON/OFF key twice to turn the unit off. The firsttime the key is pressed, the word OFF? is displayed. By pressing the ON/OFF key a second time, the OFF command is acknowledged and the gaugeis shut down.



4-2 Analog Channel Set-up

Digital Gauge (I & II) can display one Analog channel at a time. Initially the Digital Gauge must be set-up to display the selected channel. This section describes how the operator performs an initial set-up, or modify an existing channel set-up. (The procedure is identical.) A list of available analog channels is listed in Table 4-1.

* Future Software Upgrade

NOTE

The Digital Gauge (I & II) can be configured to display only (1) analog channel at a time.

Table 4-1. Default Analog Channels

Channel Description Display Code

Disable Function DSABL

Line Tension L TEN

Anchor Tension A TEN

Hook Load HK/LD

Tong Torque TTORQ

* Rotary Torque RTORQ

Pit Level PIT

Mud Flow FLOW

Mud Volume MUDVL

Trip Tank #1 TRP 1

Differential Pressure DIF P

Pump Pressure PMP P

Pressure PRESS

(The display code RTORQ appears in the menu list, but is a non functional channel)



4-2-1 Analog Application - Setup

The DIgital Gauge (I & II) can be configured to display any channel from Table 4.1. Additionally, any channel name can be modified by following the Channel Name Configuration on page 4-43. Follow the listed steps to add any analog channel, calibrate the gauge to the sensor, and set the LOW and HIGH alarms (Digital Gauge (II) - only).

Figure 4-4. Analog Screen Example - Line Tension

4-2-1-1 Configure Analog Channel Name

1. Press the key.

2. A test screen will appear and check all display segments, then disappear.

3. The Gauge type, either DG1 or DG2, will appear then disappear

4. The last active channel, will be displayed.

5. Use the or the key to scroll until an analog channel is displayed.

NOTE

If an error code, such as Cable E003, is displayed after step 3, refer to Appendix C for a listing of error code definitions. Make note of the code number and follow these steps:

a. Press the key. If Cable is intentionally discon-

nected, continue with step 4 (below this NOTE).

b. Press the key. Press twice to turn gauge off.

c. Take corrective action.

d. Re-start the procedure at Step 1, under section 4-2-1-1.

NOTE

Refer to Table 4-1. for a list of available Analog channels.



6. Press the key.

7. ALMHI (Alarm High) will appear and flash.

8. Press and hold the key, then (while holding the key) press and

hold the key for approximately 3 seconds.

9. CAL A (Calibrate Analog) will appear and flash.

10. Use the or the key to scroll until ADCHN (Add Channel) is dis-

played.

11. Press the key.

12. ANALG (Analog) will appear and flash.

13. Press the key.

14. Use the or the key to scroll until the desired channel from Table 4-1.

is displayed.

15. Press the key.

16. ANALG will appear and flash.

17. Press the key.

18. ADCHN will appear and flash.

19. Proceed to Sensor Calibration (section 4-2-1-2).

NOTE

1. BEFORE CALIBRATION, ALWAYS ENSURE YOU HAVE THE RIGHTSENSOR FOR YOUR APPLICATION.

2. If the full scale calibration range is greater than 500,000, then calibratein kilo-units. For example, to calibrate from 0 to 1 million units, enter10000 as the high limit and move the decimal point to the left oneposition. The gauge will display 1000.0 (kilo-units) if 1 million units offorce is applied to the sensor.



4-2-1-2 Analog Sensor Calibration

1. Use the or the key to scroll until CAL A is displayed.

2. Press the key.

3. M/D T (M/D TOTCO Transducer) will appear on the display.

4. Press the or the key until the desired sensor code from Table 4-2.

appears on the display.

5. If your application calls for a M/DT Pressure Transducer sensor, follow the steps listed in 4-2-1-2-1. If your application calls for 2m/V strain gauge sensor, a 0-5 Volt sensor, or a 4-20mA sensor follow the steps listed in 4-2-1-2-2.

Table 4-2. Channel and Required Sensor Type

Sensor P/N & Description Sensor Code Calibration

Code

Any strain gauge device with 2mv/V output

2mV/V BRDGE

Flow Sensor (270701-103)

Pit Probe (262622-Series) 0-5 Volt 0-5 V

Pit Probe (H10941A-Series)

5K Pressure Xducer (221042-001) M/D TOTCO M/D T

15K Pressure Xducer (221042-002) Pressure Transducer

Hookload Sensor (TCL-100K-001) 4-20mA 4-20

Tong Torque (Customer Supplied)



4-2-1-2-1 M/D TOTCO Transducer Calibration

1. Continued from Step 5 of section 4-2-1-2.

2. Press the key.

3. LOW ? and a flashing numeric value will appear on the display

4. Press the or the key to set the minimum sensor calibration value

(usually zero).

5. Press the key.

6. A/D-L (Analog to Digital Converter - Low) and the current A/D counts will be dis-played by the microprocessor.

7. Allow the A/D counts to stabilize (± 5 counts).

8. Press the key.

9. HIGH will appear and flash

NOTE

For additional information, refer to the Quick Set-Up and CalibrationProcedure - P/N 221329-002 and 221329-003.



10. Press the key.

11. Apply a known pressure load to the sensor

NOTE

ACAL (Automatic Calibration) is an alternate method for full scale calibration of a M/D TOTCO pressure sensor. A reference number (for example 1.011) will be stamped on the side of the sensor and entered by the user. Complete the steps below to calibrate the sensor to the Digital Gauge. This method will not require a full scale load be applied to the sensor.

a. Use the or the key until ACAL is displayed.

b. Press the key.

c. The default or previously entered full scale output (FSO) will appear and flash.

d. Use the or the key until the Reference

value listed on the sensor (FSPR) is displayed.

Example: FSPR = 1.010 VDC

e. Press the key 13 times. (The value displayed will

now be 13 mV less than the FSPR value entered in step 4.)

f. Press the key.

g. HIGH? and a flashing numeric value will appear on the

screen.

h. Use the or the key until the full scale pres-

sure value listed on the sensor is displayed. (Values

listed as 0 to 15K PSI or 0 to 5K PSI.

i. Press the key.

j. Proceed to Step 17.



12. Press the or the key to match the force applied to the transducer.

13. Press the key.

14. A/D-H (Analog to Digital convertor - High) and the current A/D counts will be dis-played by the internal microprocessor.


16. Press the key.

17. TEST a numeric value will appear on the screen.

18. Press the key.

19. M/D T will appear and flash on the display.

20. The sensor is now calibrated with the system.

4-2-1-2-2 Calibration of 0-5 Volt, 2 m/V Strain Gauge, and 4-20mA Sensors

Various sensors (0-5 Volt, 2m/V strain gauge, and 4-20mA) can be calibrated to the Digital Gauge. Initially the operator must perform the FULL calibration procedure. After this calibra-tion is complete, the operator may elect to modify (slightly) the calibration by selecting the LOW calibration procedure or the HIGH calibration procedure.

The FULL calibration procedure requires input of both the minimum value applied to the sen-sor and the maximum or near maximum value applied to the device. The LOW calibration pro-cedure requires only the minimum load value be applied to the sensor, then entered. The HIGH calibration procedure requires a maximum or near maximum applied load be applied to the sensor, then input for calibration The various steps are detailed below.

NOTE

To achieve accurate calibration results, it is necessary to apply a minimumof 50 percent of full scale capacity to the sensor. Full scale (100 percent)is preferable.

NOTE

A system test is performed on the Pressure Transducer to verify it is installed and operating properly. A value should be displayed which is equal to approximately 30% of full scale capacity of the sensor.



1. Continued from Step 5 of section 4-2-1-2.

2. Press the key.

3. FULL will appear and flash on the display.

4. Press the key.

5. LOW ? and a flashing numeric value will appear on the display.

6. Press the or the key to set the minimum sensor calibration

value (usually zero).

7. Press the key.

8. A/D-L (Analog to Digital Converter - Low) and the current A/D counts will be dis-played by the internal microprocessor.


10. Press the key.

11. HIGH? a flashing numeric value will appear and flash.

12. Apply a known load to the sensor.

NOTE

For additional information, refer to the following Quick Set-Up andCalibration Procedures :

4-20mA Sensors................ P/N 221329-006 & 221329-007

0-5 Volt Sensors................ P/N 221329-004

Strain Gauge Sensors....... P/N 221370

NOTE

If the Digital Gauge is wired to an external RCAL as described in Chapter 3, section 3-8-2, skip to step 13 .



13. Press the or the key to match the full scale value in step 12.

14. Press the key.

15. A/D-H (Analog to Digital convertor - High) and the current A/D counts will be displayed by the internal microprocessor.


17. Press the key.

19. The selected sensor code (from table 4-2.) will appear and flash on the display.

20. The sensor is now calibrated with the system.

21. Press the key 3 times to return to the screen.

NOTE

To achieve accurate calibration results, it is necessary to apply a minimumof 50 percent of full scale capacity to the sensor. Full scale (100 percent) ispreferable.

NOTE

Full scale A/D counts should be in a range from 3306 to 4094,approximately 3700. Refer to Appendix C trouble shooting section if thecounts exceed 4095 or fall below 3305.



4-2-2 Special Engineering Calibration

This section allows the experienced technician to calibrate or trouble-shoot the Digital Gauge (I & II) using mathematical information versus actual sensor to gauge values. Gauges can be inter-changed by duplicating the MAX, MIN, MUL, DIV, OFSET, and GAIN data from the original gauge and entering this data into the replacement gauge. The replacement gauge is calibrated to the exact parameters of the original device, eliminating numerous calibration/set-up steps.

Figure 4-5. details the mathematical formula and a representative graph.

Figure 4-5. Special Engineering Line Equation

• MAX Sets the upper limit for the analog output from the 4-20mA and/ or 0-4.5V source and sets upper limit for channel alarm values.

• MIN Sets the lower limit for the analog output from the 4-20mA and/or 0-4.5V source and sets lower limit for channel alarm values.

• MUL Calculates value used to define slope.

• DIV Calculates value used to define slope.

• OFSET Shifts calibration line up or down, but does not change slope

• GAIN Sets the gain for the Digital Gauge, automatically calculated- no user input required.

CAUTION

Do not change any of the values found in the MUL, DIV, OFSET, or GAINlocations. Alteration of these values will change the current calibration ofthe Gauge resulting in erroneous data being displayed.

X1

Y1

(X)

(Y)

X2

Y2

PT-1

PT-2

OF

FS

ET

LINE EQUATION

Y = MX + b

M = Slope

Slope = MUL DIV

RiseRun

(or)

RiseRun

= Y2 - Y1X2 - X1

b = Offset



Each of the functions contained in the ENGINEERING CALIBRATION MODE contain a group of common steps which must be completed to access the desired function. These steps will be referred to as Common Base Steps and are referenced in future set-up procedures described in all sub-sections of the Special Engineering Calibration section (4-2-2).

Common Base Steps:

1. Press the key.


3. The type of Gauge, either DG1 or DG2 will appear on the screen, then disappear.


5. Press the key.


7. Press and hold the key, then (while holding the key) press and

hold the key for approximately 3 seconds.

8. CAL A (Calibrate Analog) or CAL D (Calibrate Digital) will appear and flash.

NOTE

If an error code, such as Cable E003, is displayed after step 2, refer to Appendix B for a listing of error code definitions. Make note of the code number and follow these steps:

a. Press the key.



d. Re-start the procedure at Step 1, under section 4-2-2 Common Base Steps.

NOTE

CAL A will appear if an Analog application screen was active when Step 3 was completed. CAL D will appear if a Digital application screen was active when Step 3 was completed.



9. Press the key.

10. Use the or the key to scroll until ENGR (Engineering Calibration

Mode) is displayed.

4-2-2-1 Maximum Channel Value Assignment

The MAX (Maximum) function of the digital gauge, sets the upper limit for the 4-20mA and 0-4.5V analog output and sets the upper limit alarm values for the active channel.

1. Complete all steps listed under section 4-2-2 Common Base Steps.

2. Press the key.

3. MAX (Maximum) will appear and flash on the screen.

4. Press the key.

5. MAX and a flashing numeric value will appear on the screen.

6. Use the or the key to increase or decrease the numeric value.

7. Press the key.

8. MAX will reappear on the screen.

9. Press the key four times to return to the active viewing screen.

4-2-2-2 Minimum Channel Value Assignment

The MIN (Minimum) function of the digital gauge, sets the lower limit for the 4-20mA and 0-4.5V analog output and sets the lower limit alarm values for the active channel.


2. Press the key.

3. Use the or the key to scroll until MIN appears and flashes.

4. Press the key.

5. MIN and a flashing numeric value will appear on the screen.




7. Press the key.

8. MIN will reappear on the screen.


4-2-2-3 Multiply Factor

The Multiply factor is a mathematical component of the Line Equation Formula to determine slope. This value is a calculated value based on calibration input data. Modifying this value, in conjunc-tion with the Division factor, will cause the slope to deviate. To understand the relationship of the Multiply Factor to the formula, refer to Figure 4-5..


2. Press the key.

3. Use the or the key to scroll until MUL appears and flashes.

4. Press the key.

5. MUL and a flashing numeric value will appear on the screen.


7. Press the key.

8. MUL will reappear on the screen.


NOTE

This value should never be changed by the user. This section is madeavailable for information only, and can be used to duplicate calibration fromone gauge to another.



4-2-2-4 Divide Factor

The Divide factor is a mathematical component of the Line Equation Formula to determine slope. Modifying this value, in conjunction with the Multiply Factor, will cause the slope to deviate. To understand the relationship of the Division Factor to the formula, refer to Figure 4-5.


2. Press the key.

3. Use the or the key to scroll until DIV appears and flashes.

4. Press the key.

5. DIV (Divide) and a flashing numeric value will appear on the screen.


7. Press the key.

8. DIV will reappear on the screen.


NOTE




4-2-2-5 Offset Value

Refer to Figure 4-5.. The Offset Value, shifts the calibration line up or down, but does not change the slope of the line.


2. Press the key.

3. Use the or the key to scroll until OFSET appears and flashes.

4. Press the key.

5. OFSET (OffSet Value) and a flashing numeric value will appear on the screen.


7. Press the key.

8. OFSET will reappear on the screen.


NOTE




4-2-2-6 Set Gain

The Digital Gauge (I & II) gain can be increased or decreased by following the below steps. Gain is defined as the internal electronics signal amplification.


2. Press the key.

3. Use the or the key to scroll until GAIN appears and flashes.

4. Press the key.

5. GAIN (Gain Value) and a flashing numeric value will appear on the screen.


7. Press the key.

8. GAIN will reappear on the screen.


4-2-3 Sensor Location Configuration

As part of the calibration process of the current active channel, it is necessary to define where the Digital Gauge is receiving data- from the serial port (remote) or from the sensor (local). Follow the steps listed below to define this parameter.

1. Press the key.




5. Press the key.


NOTE




7. Press and hold the key, then (while holding the key) press and hold

the key for approximately 3 seconds.

8. CAL A (Calibrate Analog) or CAL D (Calibrate Digital) will appear and flash.

9. Press the key.

10. Use the or the key to scroll until RMT (Remote Sensor Location) is

displayed.

11. Press the key.

12. Use the or the key to scroll between LOCAL and REMOT (Remote)

location of the sensor source.

13. Press the key.

14. RMT will reappear and flash.

15. Press the key 3 times to return to the active viewing screen.

NOTE




4-3 Digital Channel Set-up

Digital Gauge (I) can receive one digital input. Digital Gauge (II) can receive two digital inputs. Dig-ital Gauge (II) must be set-up to process one or two selected channels. This section describes how the operator performs an initial set-up, or modifies an existing channel set-up. (The procedure is identical.) A list of available digital channels is listed in Table 4-3.

NOTE

For additional information, refer to the Quick Set-Up and CalibraTionProcedure - P/N 221329-005.

NOTE

Digital Gauge (II) can process two digital signals, but will only display one

digital channel at a time. To view the alternative digital channel, it will be

necessary to press the or the key until the channel appears.

If current channels need to be replaced, it will be necessary to perform the

configure channel, sensor calibration, and sensor set alarm instructions

found in this chapter. (Digital Gauge (I) - If a digital channel is selected, any

previously selected analog channel is disabled.)

Table 4-3. Default Digital Channels

Channel Description Display Code

Disable Function DSABL

Rotary RPM RTRPM

Rotations Per Minute RPM

Strokes Per Minute SPM

Strokes Per Minute (Pump 1) SPM1

Strokes Per Minute (Pump 2) SPM2



4-3-1 Digital Application - Setup

DIgital Gauge (I & II) can be configured to display any channel from Table 4-3. Additionally, any channel name can be modified by following the Channel Name Configuration on page 4-43. Follow the listed steps to add any digital channel, calibrate the gauge to the sensor, and set the LOW and HIGH alarms.

Figure 4-6. Digital Screen Example - SPM

4-3-1-1 Configure Digital Channel Name

1. Press the key.


3. The gauge type, either DG1 or DG2, will appear then disappear.


5. Use the or the key to scroll until a digital channel is displayed.

NOTE


a. Press the key.If Cable is intentionally discon-


b. Press the key. Press twice to turn the gauge off.


d. Re-start the procedure at Step 1, under section 4-3-1-1.

NOTE

Refer to Table 4-3. for a list of available Digital channels.

SPM



6. Press the key.




9. CAL D (Calibrate Digital) will appear and flash.


played.

11. Press the key.

12. ANALG (Analog) will appear and flash.

13. Use the or the key to scroll until DIG I or DIG 2 is displayed.

14. Press the key.

15. DSABL (Channel Disable) will appear and flash.

16. Use the or the key to scroll until the desired channel from Table 4-3.

is displayed.

17. Press the key.

18. DIG I or DIG 2 will appear and flash.

19. Press the key.

20. ADCHN will appear and flash.

21. Proceed to Sensor Calibration (section 4-3-1-2).

NOTE

Digital Gauge (II) is capable of processing two digital input signals, referred to as DIG I and DIG 2. It is the operator’s option which parameter is to be displayed on DIG I or DIG 2 channels.



4-3-1-2 Digital Sensor Calibration

1.Use the or the key to scroll until CAL D is displayed.

2. Press the key.

3. MAX will appear and flash.

4. Press the key.

5. The current maximum value will flash.

6. Press the or the until the full scale value of the channel is displayed.

7. Press the key.

8. MAX will appear and flash.

9. Use the until RATIO appears and flashes.

10. Press the key.

11. The current numeric value will appear and flash.

12. Press the or the until the sensor ratio (# of targets per revolution) is

displayed.

13. Press the key.

14. CAL D will appear and flash.

4-3-1-3 Decimal Point Setting

The Digital Gauge (I & II) can display values up to 3 decimal points. The operator may choose between 0, 1, 2, or 3 points. Decimal point location is selected by following the steps listed below.

1. Complete all steps in section 4-3-1-1.

NOTE

The available range of targets per revolution is .100 to 999.999.



2. Press the key.

3. Use the or the key to scroll until DECML (Decimal Setting) is dis-

played.

4. Press the key.

5. The current number of decimal points is displayed.

6. Use the or the key to move the decimal point.

7. Press the key.

8. DECML will reappear on the screen.


4-3-1-4 Minimum Channel Value Assignment

The MIN (Minimum) function of the digital gauge, sets the lower limit for the analog output from the 4-20mA and/ or 0-4.5Vsensors and sets the lower limit alarm values for the active channel.

1. Complete all steps in section 4-3-1-1.

2. Press the key.

3. Use the or the key to scroll until MIN (Minimum) is displayed.

4. Press the key.

5. A flashing numeric value will appear on the screen.


7. Press the key.

8. MIN will reappear on the screen.




4-3-2 Sensor Location Configuration

As part of the calibration process of the current active channel, it is necessary to define where the Digital Gauge is receiving data- from the serial port (remote) or from the sensor (local). Follow the steps listed below to define this parameter.

1. Complete all steps listed in section 4-3-1-1.

1. Press the key.

2. Use the or the key to scroll until RMT (Remote) is displayed.

3. Press the key.

4. Use the or the key to scroll between LOCAL and REMOT (Remote)

location of the sensor source.

5. Press the key.

6. RMT will reappear and flash.

7. Press the key 3 times to return to the active viewing screen.



4-4 Calculated Channels

Calculated channels are derived from software formulas (calculations) of single or dual inputs.

An example of a calculated single input channel is Total Strokes (Pump 1). Typically the Digital Gauge would receive the signal from the pump stroke sensor and display pump strokes in Strokes Per Minute. However, the calculated channel Total Strokes, through a mathematical formula, con-verts this data to accumulated strokes.

An example of a calculated dual input channel is Ton Mile. The Digital Gauge receives two signals, Hook Load and Wirerope Payout. Mathematically these two parameters are used to derive the data for the channel Ton Mile. (Refer to section 4-4-1 for set-up instructions)

A list of default Calculated Channels is available in Table 4-4.

Table 4-4. Calculated Channels (Default)

Channel Description Display Code Sensor Connection Required

Disable Channel DSABL NONE

Total Strokes Per Minute T SPM Digital inputs on digital channel 1 & 2. (sums SPM on digital channel 1 & 2)

Total Strokes (Pumps 1 & 2) STK12 Digital input on digital channel 1 & 2 (sums strokes on digital channel 1 & 2)

Total Strokes (Pump 2) STK 2 Digital input on digital channel 2. (sums strokes on channel 2)

Total Strokes (Pump 1) STK 1 Digital input on digital channel 1. (sums strokes on channel 1)

Weight on Bit BITWT Hookload sensor, (zero bit weight using zeroch function)

Ton Mile ** Although ton mile is a calculated channel, it is located in DIG 1 in ADCHN. Ton mile requires use of the high frequency digital 1 input channel for wirerope payout sens-ing.

TMILE Hookload sensor & proximity sensor on digital channel 1 (only)



1. Press the key.


3. The gauge type, either DG1 or DG2, will appear then disappear.



6. Press the key.






played.

11. Press the key.

12. ANALG will appear and flash on the display.

13. Use the or the key to scroll until the CALC (Calculated Channel) is

displayed.

14. Press the key.

15. DSABL (Disable Channel) will appear and flash.

NOTE






d. Re-start the procedure at Step 1, under section 4-4.



16. Use the or the key to scroll until the correct calculated channel is

displayed.

17. Press the key.

18. CALC will appear and flash.

19. Press the key 3 times to return to active viewing screen.

4-4-1 Ton Mile Channel Set-up

Although Ton Mile is a calculated channel, it is located in the ADCHN section of DIG 1. Ton Mile requires the use of the Hook Load channel and the high frequency digital 1 input channel for the wire payout (proximity) sensor. For this reason, Ton Mile has been listed in DIG 1 instead of CALC.

Follow the following steps to set-up Ton Mile as an active channel.

1. Press the key.




5. Press the key.

NOTE

Refer to Table 4-4 for a list of available Calculated channels.

NOTE



nected, continue with step 4 (below this NOTE)



d. Re-start the procedure at Step 1, under section 4-4-1.



August 14, 1997 Page 4-31






played.

10. Press the key.

11. Use the or the key to scroll until DIG 1 (Digital Channel #1) is displayed.

12. Press the key.

13. Use the or the key to scroll until TMILE (Ton Mile) is displayed.

14. LINS? and a flashing numeric value will appear.

15. Use the or the keys to enter the number of lines strung in the travel-

ing block.

16. Press the key.

17. ENGLS will appear and flash.

18. Use the or the key to scroll until correct unit of measurement is

chosen - either ENGLS (English) or METRC (Metric).

19. Press the key.

20. If ENGLS was selected, then F/PLS (Feet per Pulse) and a flashing numeric value is displayed. If METRC was selected, then M/PLS (Meters per Pulse) and a flash-ing numeric value is displayed.

21. Use the or the key to scroll until correct value is displayed.

22. Press the key.

23. DIG 1 will appear and flash.

24. Press the key 3 times to return to active viewing screen.

M/D TOTCO


4-5 User Functions Mode

These functions may require frequent access by the operator. Normal operation is suspended while accessing these functions. The USER FUNCTIONS MODE consists of the following func-tions:

• ALMHI Set Alarm Limit at upper (high) value

• ALMLO Set Alarm Limit at lower value

• BAR Set-up Bar Graph low and high limits.

• SETPT Turn ON/OFF set point function and establish deviation range (Gain/Loss Function)

• DAMPR Set degree of dampening (filtering 0-100%)

• PEAK Turn ON/OFF Peak capture feature

• LIGHT Turn ON/OFF backlighting

• BATT View battery amp hour usage

• LCD Set LCD contrast

• INQRY View current software version of Digital Gauge



Each of the functions contained in the USER FUNCTIONS MODE contain a group of common steps which must be completed to access the desired function. These steps will be referred to as Common Base Steps and are referenced in future set-up procedures.

Common Base Steps:

1. Press the key.

2. A test screen will appear and check all display segments, then disappear



5. Press the key.


4-5-1 Sensor Alarm Setting - HIGH/LOW

Digital Gauge (II) allows alarm setting, a HIGH alarm and/or a LOW alarm. These values are con-figured by the operator and entered into the gauge. If alarm limits are reached or exceeded, the alarmed channel is displayed and the relay will close. Additionally, the alarm bell on the LCD dis-play will flash and the “up” arrow or “down” arrow will illuminate indicating a high or low alarm.Follow the steps listed below to activate and define alarm values.

NOTE


a. Press the key.



d. Re-start the procedure at Step 1, under section 4-5 Common Base Steps.



1. Press the key.

2. ALMHI will appear and flash.

3. Press the key.

4. H OFF (High Alarm Off) will appear and flash.

5. Use the or the key to choose between alarm ON or OFF.

6. To disable the High alarm, select OFF and press the key. To enable the

High alarm, select ON and press the key

7. Use the or the key to set the desired high alarm value.

8. Press the key.

9. ALMHI will appear and flash.

10. Use the or the key to display ALMLO (Alarm Low).

11. Press the key.

12. L OFF (Low Alarm Off) will appear and flash.

13. Use the or the key to choose between alarm ON or OFF.

NOTE

Digital Gauge (II) allows alarm setting. Digital Gauge (I) does not contain this feature. If you are calibrating a Digital Gauge (I), disregard section 4-5-1.

NOTE

If the alarm is enabled, the current alarm value will appear and flash. If thealarm is disabled, ALMHI will appear and flash.



14. To disable the Low alarm, select OFF and press the key. To enable the

Low alarm, select ON and press the key

15. Use the or the key to set the desired low alarm value.

16. Press the key.

17. Press the key once to return to the active viewing screen.

4-5-2 Bar Graph Setup and Modification

The Digital Gauge (I & II) is capable of displaying an analog Bar Graph as a visual reference for the operator. The Bar Graph allows the operator to quickly correlate the current value to the pre-selected Bar Graph range. The range of the Bar Graph is operator setable, and is not required to represent zero to full scale capacity. If the operator elects, he may set-up the Bar Graph to monitor a specific point to point within the full scale range of the sensor.

Follow the below steps to set-up the Bar Graph or make modifications to current set-up:

1. Perform all steps listed under section 4-5 Common Base Steps.

2. Use the or the key to scroll until BAR (Bar Graph) is displayed.

3. Press the key.

4. BARLO (Bar Graph Low Limit) will appear and flash. Additionally a LCD Bar Graph will appear with the low and high limits above it.

5. Press the key.

6. The LOW limit above the Bar Graph will flash.

7. Use the or the keys to increase or decrease this numeric value.

8. Press the key.

NOTE

If the alarm is enabled, the current alarm value will appear and flash. If thealarm is disabled, ALMLO will appear and flash.



9. BARLO will appear and flash.

10. Use the or the key to scroll until BX10 flashes.

11. Press the key.

12. Press the or the keys to select X 10, X 100, or X1000 (no# is X1).

13. Press the key.

14. B X 10 will appear and flash.

15. Press the or the keys until BARHI (Bar Graph LImit High) appears

and flashes.

16. Press the key.

17. The HIGH limit above the Bar Graph will flash.


19. Press the key.

20. Press the key twice to return to the active viewing channel.

4-5-3 Set Point Set-up and Modification- (FOR DIGITAL GAUGE (II) - ONLY)

Digital Gauge (II) contains a Set Point feature which allows the operator to establish a center point within a specified range, and monitor the delta (deviation) from that center point. For Example, an operator may have a pressure application where the normal working pressure is 1000 PSI. The operator wants to monitor 100 PSI of positive and negative deviation from this value. By following the Set Point set-up procedure, the operator can create a screen which will display a Bar Graph with a center point value of 1000 PSI with a negative deviation to 900 PSI and a positive deviation to 1100 PSI.

Follow the below steps to set-up the Bar Graph or make modifications to current set-up:


2. Use the or the key to scroll until SETPT (Set Point) is displayed.



3. Press the key.

4. SP ON (Set Point On) will appear and flash.

5. Use the or the key to select SPOFF, if you do not wish to display a

set point.

6. Press the key.

7. REFPT (Reference Point) will appear. Additionally the reference point numeric value will appear and flash.


9. Press the key.

10. DELTA (Delta) will appear. Additionally the current Delta value will appear and flash.


12. Press the key.

13. Press the key once to return to the active viewing channel.

NOTE

If SPOFF is selected, proceed with the following steps:

a. Press the key.

b. Press the key once to return to the active viewing channel.

IF SP ON is selected, proceed with Step 6.

NOTE

If SETPT is active, “BAR” is not available within the menu structure of thefunctions mode. “SETPT” must be turned off to have availability to the“BAR” function.



4-5-4 Dampener Adjustment

The Digital Gauge (I & II) is capable of dampening (filtering) the input signal from the various sen-sors. The degree of dampening is selected by the operator, and may be set from zero to 100 per-cent dampened. This dampening action will allow the operator to smooth the input signal and allow better view-ability of the displayed value.

Follow the below steps to adjust the dampener or make modifications to current set-up:


2. Use the or the key to scroll until DAMPR (Dampener) is displayed.

3. Press the key.

4. A numeric value will appear and flash.

5. Use the or the key to increase or decrease this numeric value.

6. Press the key.

7. DAMPR will appear and flash.


NOTE

Un-dampened signals, which contain repetitive surges (spikes), will cause the display digits to roll. As a result, the operator may experience difficulty reading the display values.

NOTE

The larger the Dampening value, the greater the Dampening effect. Zero represents no dampening effect, while 100 represents the most dampened.



4-5-5 Peak Hold Feature (Digital Gauge II)

The Digital Gauge (II) is capable of capturing peak values for various ANALOG parameters. If selected, the Digital Gauge will capture the highest value which has exceeded the preset high alarm limit. This captured value will be displayed for 5 seconds, then revert to the current value. If a higher value results, during the 5 second capture display, then the Digital Gauge will automati-cally switch to the higher value and capture the peak. The gauge will continue to capture peaks, until the value falls below the preset high alarm limit, or is deactivated.

Follow the below steps to turn ON/OFF the Peak hold feature:


2. Use the or the key to scroll until PEAK (Peak Hold Feature) is dis-

played.

3. Press the key.

4. PK ON (Peak on) or PK OFF (Peak off) will appear on the display, dependent upon the previous configuration.

5. Use the or the key to scroll to choose either PEAK ON or OFF.

6. Press the key.

7. PEAK will appear and flash.


NOTE

The Peak Hold Feature may only be used with ANALOG channels. If aDigital Channel is selected, PEAK will not appear in the menu selection.

NOTE

For the Peak Hold to be activated, the alarm must be enabled and the valuemust exceed the High Alarm Limit.



4-5-6 BackLighting

The LCD viewing screen of Digital Gauge (I & II) can be BackLit, if the device is powered by an external source. The operator can select if backlighting is to be turned ON or OFF.

Follow the below steps to turn backlighting ON or OFF.


2. Use the or the key to scroll until Light (BackLight) is displayed.

3. Press the key.

4. Use the or the key to select LT ON (BackLight On) or LTOFF

(BackLight Off), dependent upon the preference of the operator.

5. Press the key.

6. LIGHT will appear and flash.


4-5-7 Battery Usage

Battery usage can be monitored from the main viewing screen of the Digital Gauge (I & II). The standard battery pack provided by M/D TOTCO is rated at 38 Amp Hours. As the Digital Gauge is operated, battery usage can be monitored, allowing the operator to prepare for future replacement requirements. This is a view only screen, no modifications can be made.

Follow the below steps to view current battery usage.


2. Use the or the key to scroll until INFO (Additional Information) is

displayed.

NOTE

BackLighting is available as an option and requires the Digital Gauge to bepowered by an external source. The battery pack will not power thebacklighting feature.



3. Press the key.

4. BATT (Battery) will appear and flash.

5. Press the key.

6. AMPHR (Amp Hours Used) and a numeric value will appear.

7. Press the key.

8. BATT will appear and flash.


4-5-8 Adjusting LCD contrast and Viewing Angle

The Digital Gauge (I & II) allows the operator to adjust the contrast of the LCD display. Contrast is operator selectable and set per the preference of the operator from 0 to 32. Maximum viewing angle is obtained by setting the LCD contrast at 32. Minimum viewing angle is 0.

Follow the below steps to adjust the LCD contrast:



displayed.

3. Press the key.

4. Use the or the key to scroll until LCD (Liquid Crystal Display) is dis-

played.

5. Press the key.

6. The current LCD contrast numeric value will appear.

NOTE

The Replaceable Battery Pack for Digital Gauge (I & II) contains 38 Amp Hours. Battery Life is dependent upon the application and the specific sensor or sensors attached to the Digital Gauge.



7. Use the or the key to increase or decrease this numeric value.

8. Press the key.

9. LCD will appear and flash.


4-5-9 Software Version Information

The current version of software used by the specific Digital Gauge may be viewed by accessing the INQUIRY function. This information may be valuable for future technical conversations with M/D TOTCO personnel. This is a view only screen, no modifications can be made.

Follow the below steps to view the current version of software in applicable Digital Gauge:



displayed.

3. Press the key.

4. Use the or the key to scroll until INQRY (Inquiry Information) is dis-

played.

5. Press the key.

6. DG1 will appear if the device is a Digital Gauge (I) and DG2 will appear if the device is a Digital Gauge (II). The latest version number of the software will also be displayed.

7. Press the key.

8. INQRY will appear and flash.


NOTE

The larger the LCD value, the wider the viewing angle. Zero represents themost narrow viewing angle and 32 represents the widest viewing angle.The default value is 32.



4-6 Special Functions Mode

These functions may require occasional access. Normal operation is suspended while accessing these functions. The SPECIAL FUNCTIONS MODE consists of the following functions:

• SET I Factory calibration data

• A/D View Analog to Digital counts

• NAME? Generate customized channel names

• ERASE Delete all previously stored configurations

• REMOT Establish gauge as a master, slave, or none (stand alone device)

• TEMP View internal temperature of Digital Gauge

• ZROBT Zero battery life counter

Each of the functions contained in the SPECIAL FUNCTIONS MODE contain a group of common steps which must be completed to access the desired function. These steps will be referred to as Common Base Steps and are referenced in future set-up procedures.

Common Base Steps:

1. Press the key.




5. Press the key.


NOTE


a. Press the key.



d. Re-start the procedure at Step 1, under section 4-6 Com-mon Base Steps.





8. CAL A (Calibrate Analog) or CAL D (Calibrate Analog) will appear and flash.

9. Use the or the key to scroll until SETUP (Setup More Functions) is

displayed.

4-6-1 SET I

Typically the SET I (Set Internal) function is only performed at the M/D TOTCO facility. However, if Digital Gauge (I & II) is switched from battery power to external power, it will be necessary to follow the steps listed below.


2. Press the key.

3. Use the or the key to scroll until SET I (Set Internal) appears on the

screen.

4. Press the key.

5. SCALE and a numeric value will appear on the screen.

6. Press the key.

7. I ? and a flashing numeric value will appear on the screen.

NOTE


NOTE

Unless the Digital Gauge is being converted from battery power to externalpower, do not change values located under the SET I menu. Modificationof data will invalidate the battery low indicator.



8. If you are changing from Battery Power to External Power, use the key to

change the value to read 0 (zero). If you are changing from External Power to Bat-

tery Power, simply press the key.

9. Press the key.

10. A/D and a numeric value will appear on the screen.

11. Press the key.

12. SCALE and a numeric value will reappear on the screen.

13. Press the key

14. SET I will reappear and flash.

15. Press the key 3 times to return to the active display screen.

4-6-2 Analog to Digital Counts

The Digital Gauge (I & II) contains diagnostic information to aid the technician during trouble-shooting. The Analog to Digital counts function is provided for real-time sensor A/D analysis. This is a view only screen, no modifications can be made.

Follow the below steps to view the Analog to Digital counts:


2. Press the key.

3. Use the or the key to scroll until A/D (Analog to Digital counts)

appears on the screen.

4. Press the key.

5. A/D and a numeric value will appear.

NOTE

The Analog to Digital count feature is intended for diagnostics only. The numeric value is for reference only.



6. Press the key.

7. A/D will appear and flash.

8. Press the key three times to return to the active viewing screen.

4-6-3 Channel Name Configuration

The Digital Gauge (I &II) comes shipped from the factory with specific default channels loaded into the software. Refer to Tables 4-1 and 4-3 to view the default channels. However, the operator can customize any channel name to their particular preference. Current default channel names can be modified, or complete new names can be added.

Follow the below steps to customize a channel name:


2. Press the key.

3. Use the or the key to scroll until NAME? (Name Configuration)


4. Press the key

5. The current active parameter is displayed with a flashing cursor above the left character.

6. Use the or the key to scroll until the first character is correct.

7. Press the key

8. The flashing cursor will move one position to the right. Continue with Step 6 and Step 7 until the correct name appears.

9. Press the key

10. NAME? will appear and flash.

11. Press the key three times to return to the active viewing screen



4-6-4 Erase All Stored Information

The Erase function works as a total delete action. ERASE should only be performed if all other procedures have been attempted and have failed. If the ERASE function is carried out, the Digital Gauge (I & II) will return to the original default channel name(s), calibration data, and alarm limits- as provided by the factory.

Follow the below steps to ERASE (delete) current stored data:


2. Press the key.

3. Use the or the key to scroll until ERASE (Erase current data)


4. Press the key.

5. SURE? will appear on the screen.

6. If you want to delete the current stored calibration data, custom channel names,

and alarm limit settings, Press the key

CAUTION

Performing the ERASE procedure will delete all stored calibration data,customized channel names, and alarm limit set points.

NOTE

ERASE will zero the battery amp hours. Prior to initiating an ERASE, writedown the current amp hours for the battery. Perform the ERASE function,then re-enter the amp hours using the ZROBT function (Section 4-6-7)under MENU SETUP.

NOTE

If you do not want to delete the current data, Press the key, the

key or the key



7. The Digital Gauge will revert to the original default values supplied by the factory.

8. SCALE and a numeric value will appear on the screen.

9. Press the key

10. I ? and a flashing numeric value will appear on the screen.

11. A/D (Analog to Digital Counts) and the current A/D counts will appear on the screen.

12. Press the key

13. SCALE and a numeric reference value will appear on the screen.

14. Press the key one time to return to the active viewing screen.

4-6-5 Sender/Receiver Configuration

Digital Gauge (II) can be linked (connected) with additional Digital Gauge (II)’s in a “daisy-chain” configuration. If two or more gauges are linked together, one of the devices must be designatedas the Sender (Master) device. The other gauge/s must be designated as Receiver (Slave) device/s. The Sender accepts signal input from one to three sensors and communicates this data via the RS485 serial interface to the Receiver unit. The Receiver device can accept input from it’s own sensor/s and/or serial input from the Sender gauge. The Receiver gauge can not communi-cate information to the Sender gauge.

The Digital Gauge can be set-up in one of three configurations:

• NONE - Serial input is disabled. Gauge only monitors it’s own local sensors (refer to Figure 4-7.)

• RCVR - The RCVR (Receiver) gauge can be linked with a secondary SNDR (Sender) gauge.The RCVR gauge can receive input directly from the sen-sor/s (SNDR) gauge via the serial port.(refer to Figure 4-8. and/or Figure 4-9.)

• SNDR - Serial transmitter is enabled. The gauge is a SNDR (Sender) gauge which can be linked with a secondary RCVR (Receiver) gauge. The SNDR gauge can only receive input directly from it’s own sensor/s. The SNDR gauge can send data to a remote RCVR gauge, but can not receive data from such device. (refer to Figure 4-8. and/or Figure 4-9.)

CAUTION

DO NOT CHANGE the I ? value displayed at Step 10. Modifying this valuewill result in incorrect battery life indicator operation. If externally powered,enter 0 and press ACK. If battery powered, only press ACK.



Figure 4-7. “NONE” Configuration Selection

Figure 4-8. Sender/Receiver Configuration “A”

Figure 4-9. Sender/Receiver Configuration “B”

Digital

Digital

Analog

NONE

Digital

Digital

Analog

SENDER RECEIVER

Sensor

Sensor

SENDER RECEIVER

Sensor



Follow the below steps to configure the Digital Gauge as a Sender or Receiver:


2. Press the key.

3. Use the or the key to scroll until REMOT (Remote Configuration)


4. Press the key.

5. SNDR (Sender) will appear and flash on the screen.

6. Use the or the key to scroll between SNDR (Sender), RCVR

(Receiver), and NONE (Neither).

7. Press the key.

8. REMOT will appear and flash on the screen.

9. Press the key 3 times to return to the active viewing screen

4-6-6 View Internal Gauge Temperature

The Digital Gauge (I & II) contains diagnostic information to aid the technician. The Temperature function is intended for that purpose. The temperature displayed represents the internal tempera-ture of the Digital Gauge- not the ambient temperature.This is a view only screen, no modifications can be made. The temperature sensor is used to control the update rate of the LCD and to calcu-late battery life expectancy.

Follow the below steps to view the internal Temperature of the Gauge:


2. Press the key.

3. Use the or the key to scroll until TEMP (Internal Gauge Tempera-

ture) appears on the screen.

4. Press the key.

5. DEG F (Degrees Fahrenheit) and the current internal gauge temperature will appear.



6. Press the key.

7. TEMP will appear and flash.


4-6-7 Battery Replacement or Changing from Battery Powered to External Powered

When changing out an expended battery pack or changing from a battery pack to external power, it is necessary to “zero-out” the battery life counter. If you are replacing the expended battery with a new battery or switching to external power, simply follow the steps listed below.

To Zero the Battery Life Counter, perform the below steps:


2. Press the key.

3. Use the or the key to scroll until ZROBT (Zero Battery) appears on

the screen

4. Press the key.

5. ZROBT and a numeric amp hour value will appear and flash.

6. Use the or the key set amp hours as required.

7. Press the key.

NOTE

The Temperature feature is intended for diagnostics only. The displayedtemperature value represents the temperature inside the gauge- not externalatmospheric temperature.

NOTE

Only perform this activity when replacing battery packs or switching frombattery power to external power.



8. ZROBT will appear and flash.


NOTE

1. You must zero out the counter any time a battery is replaced with a newbattery or if the Gauge is switched to external power.

(OR)

2. If a battery is replaced with a used battery, you must set the counter to match the amp hours which remain in the used battery.


APPENDIX APARTS LIST

A-1 Introduction

Included in this appendix are lists of all components and assemblies. The list, compiled in refer-ence designator order, contains the part description, manufacturer name, and part number. Most electronic components used are standard, commercially available items. Manufacturers’ part num-bers have been omitted on those parts which are easily obtained by using the description. Although some parts may be available from several manufacturers, only one is listed for conve-nience.

Spare parts and repair parts are available from M/D TOTCO. When specifying parts, please include the following information (as applicable):

1. Instrument model number or PCB assembly number

2. Instrument serial number or PCB assembly date of manufacture

3. Part description

4. Manufacturer’s name and part number

5. Reference designator (if applicable)

WARNING

When receiving or handling spare parts, CMOS devices must be protectedfrom static discharge. All maintenance personnel must observe properhandling and grounding procedures when handling them.

August 14, 1997 Page A-1M/D TOTCO

Appendix A Digital Gauge I & IIPARTS LIST Manual 26-102

A-2Digital Gauge I Assembly

Page A-2 August 14, 1997M/D TOTCO

Digital Gauge I & II APPENDIX AManual 26-102 PARTS LIST

Table A-1. Digital Gauge I Assembly 221003-001 - Basic 6" Bezel

Find Number Part Number Description Quantity

7 221009-001 CASE 1

8 221016-001 6 INCH BEZEL 1

10 221018-001 PIEZO PANEL 1

11 221019-001 BEZEL GASKET 1

12 221013-001 LABEL, I.S. 1

13 221027-001 LABEL, ELCTRSTC WARNING 1

14 220940-001 PCB ASSY, LCD 1

16 220944-001 PCB ASSY, BARR/INTFC 1

17 220948-001 PCB ASSY, CPU 1

19 221045-001 DAMPENING FOAM 2


21 G177-3MA LOCK WASHER 4

22 999321-116 LOCK WASHER, HEL #6 SST 3

23 999376-011 STANDOFF, 6-32 3

24 999383-131 6-32x.50 SCRW FILH SLTD SST 4

25 999202-121 STANDOFF, .25, HEX,FEMALE 4

26 999445-001 FLT WASHER, #6x.37x.016 SST 3

27 G180A-02743 FLT WASHR, #10, SST 3

28 999449-568 SCREW, 6-32 x .37 PNHD SST 3

29 999391-150 SCREW, 6-32 x .50, SST, TRUSS HD 4

30 J812-10TS SCREW, 10-32x1.125, SST, TRUSS HD 4

31 221052-001 LABEL, CONNECTOR 1


33 G180A-03143 WASHER, FLAT, #10, CRES 1

34 100796-012A0 O-RING, .50X.38X.06 1

35 999445-010 WASHER, FLAT, .39 X.63X.032. 1

36 972808-001 VENT, BREATHER VALVE 1

37 2800-01000 NUT, HEX, 10-32, NYLONLOCK 4

38 991221-001 KLEER PATCH, .3375 X.5625 2

39 993004-007 DESICANT BAG, 2 GRAMS 1

N/S 971198-009 PROTECTIVE CAP (SHELL 8) 3




Table A-2. Digital Gauge I Assembly 221003-002 - 6" Bezel with Backlit LCD


7 221009-001 CASE 1

8 221016-001 6 INCH BEZEL 1

10 221018-001 PIEZO PANEL 1

11 221019-001 BEZEL GASKET 1

12 221013-001 LABEL, I.S. 1


15 220940-002 PCB ASSY, LCD-DIG GAUGE 1


17 220948-001 PCB ASSY, CPU 1



21 G177-3MA LOCK WASHER, #10 4


23 999376-011 STANDOFF, 6-32 3


25 999202-121 HEX NUT, #10-32, SST 4

26 999445-001 FLT WASHER, #6x.37x.016 SST 3

27 G180A-02743 FLT WASHR, #10x.43x.032 SST 3

28 999449-568 SCREW, 6-32 x .37 PNHD SST 3






34 100796-012A0 O-RING, .50X.38X.06 1

35 999445-010 WASHER, FLAT, .39 X.63X.032. 1



38 991221-001 KLEER PATCH, .3375 X.5625 2






Table A-3. Digital Gauge I Assembly 221003-003 - 6" Bezel with Battery Pack


7 221009-001 CASE 1

8 221016-001 6 INCH BEZEL 1

10 221018-001 PIEZO PANEL 1

11 221019-001 BEZEL GASKET 1

12 221013-001 LABEL, I.S. 1




17 220948-001 PCB ASSY, CPU 1

18 221004-001 BATTERY, LITHIUM 1





23 999376-011 STANDOFF, 6-32 3


25 999202-121 HEX NUT, #10-32, SST 4

26 999445-001 FLT WASHER, #6x.37x.016 SST 3


28 999449-568 SCREW, 6-32 x .37 PNHD SST 3






34 100796-012A0 O-RING, .50X.38X.06 1

35 999445-010 WASHER, FLAT, .39 X.63X.032. 1



38 991221-001 KLEER PATCH, .3375 X.5625 2






Table A-4. Digital Gauge I Assembly 221003-004 - Basic 10" Bezel


7 221009-001 CASE 1

9 221016-002 10 INCH BEZEL 1

10 221018-001 PIEZO PANEL 1

11 221019-001 BEZEL GASKET 1

12 221013-001 LABEL, I.S. 1




17 220948-001 PCB ASSY, CPU 1





23 999376-011 STANDOFF, 6-32 3


25 999202-121 HEX NUT, #10-32, SST 4

26 999445-001 FLT WASHER, #6x.37x.016 SST 3


28 999449-568 SCREW, 6-32 x .37 PNHD SST 3






34 100796-012A0 O-RING, .50X.38X.06 1

35 999445-010 WASHER, FLAT, .39 X.63X.032. 1



38 991221-001 KLEER PATCH, .3375 X.5625 2






Table A-5. Digital Gauge I Assembly 221003-005 - 10" Bezel with Bacllit LCD


7 221009-001 CASE 1

9 221016-002 10 INCH BEZEL 1

10 221018-001 PIEZO PANEL 1

11 221019-001 BEZEL GASKET 1

12 221013-001 LABEL, I.S. 1




17 220948-001 PCB ASSY, CPU 1





23 999376-011 STANDOFF, 6-32 3


25 999202-121 HEX NUT, #10-32, SST 4

26 999445-001 FLT WASHER, #6x.37x.016 SST 3


28 999449-568 SCREW, 6-32 x .37 PNHD SST 3






34 100796-012A0 O-RING, .50X.38X.06 1

35 999445-010 WASHER, FLAT, .39 X.63X.032. 1



38 991221-001 KLEER PATCH, .3375 X.5625 2






Table A-6. Digital Gauge I Assembly 221003-006 - 10" Bezel with Battery Pack


7 221009-001 CASE 1

9 221016-002 10 INCH BEZEL 1

10 221018-001 PIEZO PANEL 1

11 221019-001 BEZEL GASKET 1

12 221013-001 LABEL, I.S. 1




17 220948-001 PCB ASSY, CPU 1

18 221004-001 BATTERY, LITHIUM 1





23 999376-011 STANDOFF, 6-32 3


25 999202-121 HEX NUT, #10-32, SST 4

26 999445-001 FLT WASHER, #6x.37x.016 SST 3


28 999449-568 SCREW, 6-32 x .37 PNHD SST 3






34 100796-012A0 O-RING, .50X.38X.06 1

35 999445-010 WASHER, FLAT, .39 X.63X.032. 1



38 991221-001 KLEER PATCH, .3375 X.5625 2






A-3 Digital Gauge II Assembly



Table A-7. Digital Gauge II Assembly 221010-001 - Basic 6" Bezel




10 220948-002 PCB ASSY, CPU 1

12 221009-001 CASE 1

13 221013-002 LABEL, I.S. 1

14 221016-001 6 INCH BEZEL 1

16 221018-001 PIEZO PANEL 1

17 221019-001 BEZEL GASKET 1






23 999376-011 STANDOFF, 6-32 3


25 999202-121 HEX NUT, #10-32, SST 4

26 999445-001 FLT WASHER, #6x.37x.016 SST 3


28 999449-568 SCREW, 6-32 x .37 PNHD SST 3






34 100796-012A0 O-RING, .50X.38X.06 1

35 999445-010 WASHER, FLAT, .39 X.63X.032. 1



38 991221-001 KLEER PATCH, .3375 X.5625 2






Table A-8. Digital Gauge II Assembly 221010-002 - 6" Bezel with Backlit LCD




10 220948-002 PCB ASSY, CPU 1

12 221009-001 CASE 1

13 221013-002 LABEL, I.S. 1

14 221016-001 6 INCH BEZEL 1

16 221018-001 PIEZO PANEL 1

17 221019-001 BEZEL GASKET 1






23 999376-011 STANDOFF, 6-32 3


25 999202-121 HEX NUT, #10-32, SST 4

26 999445-001 FLT WASHER, #6x.37x.016 SST 3


28 999449-568 SCREW, 6-32 x .37 PNHD SST 3






34 100796-012A0 O-RING, .50X.38X.06 1

35 999445-010 WASHER, FLAT, .39 X.63X.032. 1



38 991221-001 KLEER PATCH, .3375 X.5625 2






Table A-9. Digital Gauge II Assembly 221010-003 - 6" Bezel with Battery Pack




10 220948-002 PCB ASSY, CPU 1

11 221004-001 BATTERY, LITHIUM, TL5930 1

12 221009-001 CASE 1

13 221013-002 LABEL, I.S. 1

14 221016-001 6 INCH BEZEL 1

16 221018-001 PIEZO PANEL 1

17 221019-001 BEZEL GASKET 1






23 999376-011 STANDOFF, 6-32 3


25 999202-121 HEX NUT, #10-32, SST 4

26 999445-001 FLT WASHER, #6x.37x.016 SST 3


28 999449-568 SCREW, 6-32 x .37 PNHD SST 3






34 100796-012A0 O-RING, .50X.38X.06 1

35 999445-010 WASHER, FLAT, .39 X.63X.032. 1



38 991221-001 KLEER PATCH, .3375 X.5625 2






Table A-10. Digital Gauge II Assembly 221010-004 - Basic 10" Bezel




10 220948-002 PCB ASSY, CPU 1

12 221009-001 CASE 1

13 221013-002 LABEL, I.S. 1

15 221016-002 10 INCH BEZEL 1

16 221018-001 PIEZO PANEL 1

17 221019-001 BEZEL GASKET 1






23 999376-011 STANDOFF, 6-32 3


25 999202-121 HEX NUT, #10-32, SST 4

26 999445-001 FLT WASHER, #6x.37x.016 SST 3


28 999449-568 SCREW, 6-32 x .37 PNHD SST 3






34 100796-012A0 O-RING, .50X.38X.06 1

35 999445-010 WASHER, FLAT, .39 X.63X.032. 1



38 991221-001 KLEER PATCH, .3375 X.5625 2






Table A-11. Digital Gauge II Assembly 221010-005 - 10" Bezel with Backlit LCD




10 220948-002 PCB ASSY, CPU 1

12 221009-001 CASE 1

13 221013-002 LABEL, I.S. 1

14 221016-002 10 INCH BEZEL 1

16 221018-001 PIEZO PANEL 1

17 221019-001 BEZEL GASKET 1






23 999376-011 STANDOFF, 6-32 3


25 999202-121 HEX NUT, #10-32, SST 4

26 999445-001 FLT WASHER, #6x.37x.016 SST 3


28 999449-568 SCREW, 6-32 x .37 PNHD SST 3






34 100796-012A0 O-RING, .50X.38X.06 1

35 999445-010 WASHER, FLAT, .39 X.63X.032. 1



38 991221-001 KLEER PATCH, .3375 X.5625 2






Table A-12. Digital Gauge II Assembly 221010-006 - 10" Bezel with Battery Pack




10 220948-002 PCB ASSY, CPU 1

11 221004-001 BATTERY, LITHIUM, TL5930 1

12 221009-001 CASE 1

13 221013-002 LABEL, I.S. 1

14 221016-002 10 INCH BEZEL 1

16 221018-001 PIEZO PANEL 1

17 221019-001 BEZEL GASKET 1






23 999376-011 STANDOFF, 6-32 3


25 999202-121 HEX NUT, #10-32, SST 4

26 999445-001 FLT WASHER, #6x.37x.016 SST 3


28 999449-568 SCREW, 6-32 x .37 PNHD SST 3






34 100796-012A0 O-RING, .50X.38X.06 1

35 999445-010 WASHER, FLAT, .39 X.63X.032. 1



38 991221-001 KLEER PATCH, .3375 X.5625 2






A-4 Suction Grip Tool

The following tool, P/N 999784-001, is used to aid removal of the Piezo (Display) Panel, P/N 221018-001, from the Digital Gauge (I & II). Instructions on use of this suction grip tool are found in Appendix C - Troubleshooting.

Figure A-1. Suction Grip Tool - P/N 999784-001


APPENDIX BSPECIFICATIONS

B-1 Certification Documents

• CENELEC EEx ia IIB T4

• IEC 79-11 Ex ia IIB T4Class I Div 1 Gas groups C,D

B-2 Hardware Specifications

B-2-1 Housing Characteristics

• Dimensions: 6.25" (Dia) x 4.3" (Deep) (with External Battery Pack) 6.25" (Dia) x 2.75" (Deep) (without External Battery Pack)

• Panel Mount and Box mount

• Material: Plastic (Valox) molded in one piece part

• Chemical resistant (both alkaline and acids)

• Two bezels are designed to accommodate panel mounting to the Martin-Decker standard bezel diameter and the TOTCO standard bezel diameter.

B-2-2 Connectors

• J1- 4 pin for External Power (battery or barrier external power)

• J2- 3 pin for IS alarm (only active on DIGITAL GAUGE II)

• J3- 18 pin for Analog and Digital Input

• J4- 4 pin for Analog output (only active on DIGITAL GAUGE II)

Figure B-1. Connectors

J1

J2 J4

J3

August 14, 1997 Page B-1M/D TOTCO

Appendix B Digital Gauge I & IISPECIFICATIONS Manual 26-102

B-2-3 Gauge Weight

• 4 LBS (approximate)

B-2-4 Keypad

• Piezo Electric

• 5 Keys - Mode, ACK, Up Arrow, Down Arrow, ON/OFF

• Window Construction - .062" Polycarbonate

Figure B-2. Ditigal Gauge I & II Keypad

B-2-5 Operating/Storage Temperature

Table B-1 lists, the operating and storage temperature specifications for Digital Gauge I & II.

B-2-6 Power Source(s)

• Battery Power

• External Power

B-2-7 Battery Specifications

Table B-1. Operating/Storage Temperature

SPECIFICATIONS Digital Gauge II

Operating Temp -40° C to +70° C

Storage Temp -55° C to +75° C

Table B-2. Battery Specifications

BATTERY SPECIFICATIONS

Open Circuit Voltage 7.2 Volts

Amp Hour Life 38 Amp/Hrs

Safety Description 7.2V VOC, 145mA,

Ci=0, Li=0

Page B-2 August 14, 1997M/D TOTCO

Digital Gauge I & II APPENDIX BManual 26-102 SPECIFICATIONS

B-2-8 Battery Life Expectancy

B-2-9 LCD Specifications

B-2-10 LCD Viewing Angle

• 35° at 12:00 position

• 60° (approx) at 9:00 or 3:00 position

• 60° (approx) for Direct Drive portion display

B-3 Analog Input

B-3-1 Analog Input Specifications

• Interface Devices: DAQ digital PWM output, Pit Probes, external 0-5V devices

• Input Impedance: 200K ohms

• 12 bit A/D input resolution

B-3-2 Accuracy

• Total error: .25%

• Temperature drift: .0062%/C°

Table B-3. Battery Life Expectancy

BATTERY LIFE- DIgital Gauge I & II

Application Life Expectancy

Limit Switch Application approx. 8 months

Press Trans Application approx. 7 months

Proximity Switch approx. 6 months

Table B-4. LCD Specifications

LCD Response Time

-30° C to -40° C -20° C to -30° C 0° C to -20° C 0° C to +20° C

1.5 second 300 msecond 200 msecond 100 msecond



B-3-3 Analog Input Compatible Devices

Listed in Table 2-2 are barrier requirements for various sensor inputs to the Digital Gauge.

B-3-4 Strain Gauge Types

Listed in Table B-6 are the acceptable RCAL values and strain gauge types for the Digital Gauge.

NOTE

Always refer to Digital Gauge installation and Control Drawings 221014and 219569.

Table B-5. Analog Input Compatible Devices

ANALOG INPUT BARRIER REQUIREMENT

M/D TOTCO DAQ (barrierless) Yes - See Installation Section

M/D TOTCO DAQ (UL) None

M/D TOTCO Pressure Transducer None

4-20mA (externally sourced - isolated) Yes - See Installation Section

Strain gauge (1.8 to 2.2 mv/V) None

Pit Probe (3 wire Pot) None

Table B-6. 2mv/V Strain Gauge Ohm Resistance and RCAL value

ExternalJ Box RCAL

ResistorPart Number

Description/Information



98.63K 4730-98623 Typical 350 OHM Bridge, 1MV/V (Stand 100K -1.37K=98.63K)Typical 700 OHM Bridge, 2 MV/V (Stand 100K -1.37K=48.63K)




1 MEG 4720-10045 Typical 5000OHM Bridge, 1.5 MV/V (Stand 1MEG -1.37K=INSIGF)

Connect (2)748.63K To

Obtain 1.5MEG

Use (2) 4730-74833

Typical 5000 OHM Bridge, 1 MV/V (Stand 1.5MEG -1.37K=INSIGF)



B-3-5 Pressure Transducer Specifications

Listed in Table B-7 are the specifications for the 5K (P/N 221042-001) and 15K (P/N 221042-002) Pressure Transducers.

* Burst Pressure limited by pressure rating of WECO 1502 union.

Table B-7. Pressure Transducer Specifications

SPECIFICATIONS

5K SENSOR P/N 221042-001

15K SENSOR P/N 221042-002

Connection Weco 1502 Weco 1502

Construction 304 Stainless Steel 304 Stainless Steel

Wetted Material Inconel X-750 Inconel X-750

Weight 5.5 lbs 5.5 lbs

Shock Maximum 100 G’s (3 axis) 100 G’s (3 axis)

Proof Pressure 8.35K PSI 25K PSI

Burst Pressure * 15K PSI 22.5K PIS

Enclosure Classification NEMA 4X NEMA 4X

Insulation Resistance > 100 Meg Ohms to case > 100 Meg Ohms to case

Non-linearity < 0.25% FSO < 0.25% FSO

Hysteresis < 0.10% FSO < 0.10% FSO

Repeatability < 0.10% FSO < 0.10% FSO

Temp effect on Zero < ± 1% FSO per 100° F < ± 1% FSO per 100° F

Temp effect on Span < ± 1% FSO per 100° F < ± 1% FSO per 100° F

Operating Temp -40° F to +250° F 40° F to +250° F

Storage Temp -67° F to + 302° F -67° F to + 302° F

Long Term Stability < ± 0.5% FSO per 6 months

< ± 0.5% FSO per 6 months

Voltage OUT 200 mv/v 200 mv/v

Voltage IN 3.5 - 5 V max 3.5 - 5 V max



B-4 Digital Input

B-4-1 Digital Input #1 Specifications

• Low Frequency Input:

A. Bandwidth- 70Hz (±9hz)

B. Applications- limit switches, proximity switches

• High Frequency Input:

A. Bandwidth- 1 Khz (±9hz)

B. Applications- ton mile, 1khz devices with barriers

• Trip point for proximity sensor: 1.65 ma (±.1ma)

• Voltage trip point: Hi=4.1V(±.1V), Vtrip lo=3.9V(±.1V)

B-4-2 Digital Input #2 Specifications

• Low Frequency Input only.

A. Bandwidth- 70 hz(±9hz)

B. Applications- Limit switches, proximity switches

B-4-3 Digital Input Compatible Devices

In Table B-7, the various compatible digital input devices are listed and if it requires a barrier.

Table B-8. Digital Input Compatible Devices

Input Devices Barrier Requirement

Limit Switch None

MDT Proximity Sensor None

TTL/CMOS Yes

Isolated TTL/CMOS Yes



B-5 Analog Output

B-5-1 Voltage Output

B-5-1-1 Specifications

• Minimum load resistor - 25K

• Output impedance - 500 ohms (±100)

• D/A resolution - 8 bits

• Accuracy - 1.65%

• Temperature drift - .01%/C°

B-5-1-2 Compatible Devices

In Table B-8, the various compatible Analog Voltage output devices are listed and if it requires a barrier.

B-5-2 4-20mA Output

B-5-2-1 Specifications

• D/A Resolution - 8 bits

• Range - 4mA (± 0.1mA) to 20 mA (± 0.3mA)

• Loop drop max - 5 volts at 20 mA

NOTE

The Following Specifications apply to Digital Gauge II ONLY.

NOTE

Always refer to Digital Gauge Installation and Control Drawings 221014and 219569.

Table B-9. Voltage Output Compatible Devices

Output Device Barrier Requirement

M/D TOTCO DAQ None

Isolated 0-4 V Yes

Non-Isolated 0-4 V Yes



B-5-2-2 Compatible Devices

In Table B-9, the various compatible analog 4-20mA output devices are listed, along with the required barrier type.

B-5-3 Interface Configurations/ Barrier Requirements

In Table B-10, the various gauge installation configurations are listed with their associated barrier requirements.

Table B-10. 4-20 mA Output Compatible Devices

Output Device Barrier Requirement

Non-isolated 4-20mA P/N H10992A-787SP

Isolated 4-20mA P/N 951540-017

Table B-11. Interface Configurations/Barrier Requirements

Configuration Barrier Requirement

Gauge to Gauge None

Gauge to Safe Area- RS485/WITS device

P/N H10992A-755A

Gauge to Safe Area- RS232 device

P/N H10992A-755A


APPENDIX CTROUBLESHOOTING

C-1 Introduction

The following table lists the various error codes the Digital Gauge II can present you with, the pos-sible causes, and corrective actions necessary to return the system to optimal performance.

C-2 Digital Gauge Does Not Function

If the Digital Gauge (I & II) does not function, reference Table C-1 for possible solution.

Table C-1. Troubleshooting

Problem Possible Cause Corrective Action

Gauge is not turned on. Press the ON/OFF but-ton on the keypad.

Dead battery. Replace battery.

Faulty External Power.Check power wiring

Gauge does not turn-on Check power source.

Defective keypad.

Replace keypad (P/N 221018-001).

Replace CPU PCB (P/N 22948-001 for Digital Gauge I) or (P/N 22948-002 for Digital Gauge II).

August 14, 1997 Page C-1M/D TOTCO

Appendix C Digital Gauge I & IITROUBLESHOOTING Manual 26-102

C-3 Error Code Troubleshooting Table

Table C-2. Digital Gauge I & II Error Codes

Error Code What it Means Possible Cause Corrective Action

EPROM

E002

Processor is seeing "bad" data in this memory.

Initial battery installationNone. This happens the first time the battery is installed after leaving the factory. Press ACK and proceed with setup.

"Bad" data in memoryCycle power on/off several times to re-initialize thememory.

U4 on CPU PCB badReplace CPU PCB (P/N 220948-001 for Digital Gauge I) or (P/N 220948-002 for Digital Gauge II).

CABLE

EOO3

System has detected a prob-lem with a cable

Cable shields not prop-erly grounded.

Ground all cable shields as shown in Field ServiceBulletin 274 and Figures 3-45 and 3-46.

Cables not properly installed or connected

Check all wiring.

Cut CableUsing an ohmmeter, verify 0 ohms betweenpin B and pin U on J3 cable connector. If there is any resistance the cable could be cut.

5VOLT

E004

System has detected an overcurrent fault and has shut down sen-sor voltage to prevent battery drain.

Cable shortCheck cable for short. To recover from this fault, turn the gauge off, then back on.

Sensor shortCheck sensor for short. To recover from this fault, turn the gauge off, then back on.

Sensor was connected to Gauge when Gauge was "on"

"Hot-Swapping" sensors will cause this error to recover. Turn Gauge OFF, then ON.

Battery almost dead.Perform battery test per 221022-005 Test Proce-dure.

Cable shields not prop-erly grounded.

Ground all cable shields as shown in Field ServiceBulletin 274 and Figures 3-45 and 3-46.

NOCHN

E005

Operator did not select an active channel.

No active channel selected

Follow instructions in Chapter 4 for selecting an active channel.

TEMP

E006

Temperature data is invalid- Gauge displays default value (room temp)

Bad LCD PCB Replace LCD PCB (P/N 220940-001)

Page C-2 August 14, 1997M/D TOTCO

Digital Gauge I & II Appendix CManual 26-102 TROUBLESHOOTING

-

-

C-4 Battery Test Procedure (P/N 221022-005)

A battery pack is considered "Good" if both of the following tests are passed:

1. With a voltmeter measure the voltage between Pin A and Pin B on the battery connector. Verify the open circuit voltage reading is 7.06V or greater at room tem-perature. If it is good, continue to Step 2.

2. Place a 392 Ohm resistor (P/N 911440-258) between Pin A and Pin B on the bat-tery connector. (This creates a 15mA load on the battery.) Verify the loaded volt-age reading of 5.60V - 6.10V at room temperature.

C-5 Digital Gauge Connectors

Digital Gauge (I & II) both have four male connector pins located on the backside of the case. If a battery is attached, the power connector is not exposed. The four connectors are as follows:

• Alarm Relay Connector

• Sensor Input Connector

• Analog Output Connector

• Power Connector

888888

The Gauge is set-up as a receiver (slave) and is not receiving data from the sender (master) Gauge.

Master Gauge is not configured as a master.

Configure Master Gauge. See Section 4-6-5 of thismanual, or follow quick Calibration and Set-up Procedure 221329-001.

Bad cable between two Gauges.

Check cable and wiring.

Slave Gauge is not con-figed as a slave.

Configure Slave Gauge. See Section 4-6-5 of this manual, or follow quick Calibration and Set-up Procedure 221329-001.

NOTE

The Alarm Relay connector and the Analog Output connectors are inactiveon Digital Gauge I.

Table C-2. Digital Gauge I & II Error Codes (Continued)

Error Code What it Means Possible Cause Corrective Action



C-5-1 Alarm Relay Connector

The alarm relay connector is located on the backside of the Digital Gauge. This three pin connec-tor is used to connect a cable interconnect between the digital gauge and an external alarm device.

Figure C-1. Alarm Relay Connector

Table C-3. Alarm Relay Connector


A Alarm Relay Output

B Alarm Relay Output

C Not used

B

C

A



C-5-2 Sensor Input Connector

The sensor input connector is located on the backside of the Digital Gauge. This (18) pin connec-tor is used to connect the sensor cable from the various sensor inputs with the Digital Gauge.

Figure C-2. Sensor Input Connector

Table C-4. Sensor Input Connector


A Analog signal (+) input

B Cable Connected input

C Output (+) input

D RCAL (-) output

E RS485 (-) input/output

F RS485 (+) input/output

G High Frequency select - digital chnl 1

H Proximity sensor select - digital chnl 1

J Proximity sensor select - digital chnl 2

K 4-20 mA select line

L Analog signal - input

M VREF (connect to analog signal- for 0-5V input)

N Pulsed 4V output (not active)

A

B

C

D

E

F

G

H J K

L

M

N

P

R

S

T

U



C-5-3 Analog Output Connector

The analog output connector is located on the backside of the Digital Gauge. This four pin connec-tor is used to export an analog output to external instrumentation.

Figure C-3. Analog Output Connector

P RCAL (+) (5K ohm strain gauges- 2 mv/v)

R RCAL (+) (M/D TOTCO pressure xducers)

S Low Frequency input for digital chnl 1

T Low Frequency input for digital chnl 2

U Gauge circuit ground (connect to I.S. ground when powered by external source)

Table C-5. Analog Output Connector


A 4-20mA Output (-)

B 4-20mA Output (+)

C Ground

D 0-4.5 V Output

NOTE

4-20mA output must be externally sourced and isolated.

Table C-4. Sensor Input Connector


A

B

C

D



C-5-4 Power Input Connector

The power input connector is located on the back of the digital gauge. This four pin connector is used to connect power from the power source to the digital gauge, either battery or external power.

Figure C-4. Power Input Connector

Table C-6. Power Input Connector


A + Battery I.S. Power

B Ground

C Not used

D + External Power In

AB

C D



C-6 CPU Board (Display & Keypad) Removal

Place the pad surface of the suction grip tool (P/N 9999784-001) to the face of the CPU Board (220948-001/002) of the Digital Gauge (I & II). Push plunger in fully, using rapid motion. Then let plunger spring back out. See Figure C-4. Repeat sequence until plunger stays in and red line is no longer visible. The unit is now attached with maximum holding power (maximum grip).

Slowly pull upward (vertically) with the handle of the suction tool, while gently rocking the tool. This action will unplug the Keypad Assembly from the Interface Board. To release the Keypad from the suction tool, lift the tab near the edge of the pad.

Figure C-5. Suction Grip Tool

NOTE

Reappearance of the red line indicates air has leaked back into the systemand the unit is losing its grip. Operating the plunger once or twice will restoremaximum grip.

PAD

PLUNGER

HANDLE

TAB


Digita l Gauge I & II Appendix CManual 26-102 TROUBLESHOOTING

C-7 Cable Asse mblies

Complete cable assemblies are available from M/D TOTCO in two varieties- standard and marine. Refer to Table C-7 to complete the length dash number.

The following cable assembly drawings are included at the end of Appendix C.

• 221015 Cable assembly, sensor 4 pages

• 221039 Cable assembly, power 1 page

• 221040 Cable assembly, alarm 1 page

• 221041 Cable assembly, analog out 1 page

• 221064 Cable assembly, hook load 1 page

Table C-7. Cable Length Dash Number Designators

Cable Length Part Number Designators

Dash No.

Length in FT

Dash No.

Length in FT

Dash No.

Length in FT

Dash No.

Length in FT

01 5 11 55 21 150 31 325

02 10 12 60 22 160 32 350

03 15 13 65 23 170 33 375

04 20 14 70 24 180 34 400

05 25 15 75 25 190 35 425

06 30 16 100 26 200 36 450

07 35 17 110 27 225 37 475

08 40 18 120 28 250 38 500

09 45 19 130 29 275 39 550

10 50 20 140 30 300 40 600

August 14 , 1997 Page C-9M/D TOTCO



APPENDIX DMENU TREES

D-1 Overview

This section of the manual is intended to navigate the operator through the various menu levels associated with Digital Gauge II. The menu trees represent flow charts and move in an orderly pro-gression from point A to point Z, denoting all of the steps along the path. Symbols, such as the ACK button, are used to represent required actions by the operator. Alpha codes in black boxes denote display messages which result from operator action.

D-2 Definition of Symbols

The menu trees found in Appendix D utilize symbols to denote various actions or results from actions. In Table D-1, the various symbols are defined.

Table D-1 Definition of Symbols

Symbol Action or Result

The ACK symbol acts as an enter key. By pressing the ACK key, numeric values are acknowledged or the device is instructed to pro-ceed forward.

The MODE symbol acts as an ESC (escape) or back-up key. This key is used after steps are completed and the procedure requires returning to the previous screen.

The ARROWS symbol is used to scroll through the various menu selections and increase or decrease numeric values.

The CIRCLE/POUND symbol represents required action by the operator. The operator must accept or change the displayed numeric value.

An ARROW LINE symbol is used to direct the operator through the menu tree. The flow of the tree follows the direction of the arrows.

A BLACK BOX symbol denotes an alpha message displayed on the screen, which is a resultant of a specific step within the menu tree.

#

STIME

August 14, 1997 Page D-1M/D TOTCO

Appendix D Digital Gauge I & II

MENU TREES Manual 26-102

USER DISPLAY MODE

ALMHI

ALMLO

BAR

H OFF

H ON #

BARLO

L OFF

L ON #

#

B X 10 B X 10 B X 100 B X 1000

BARHI #

SETPT SP ON REFPT # DELTA #

(CONTINUED)

SPOFF

Page D-2 August 14, 1997M/D TOTCO

Digital Gauge I & II APPENDIX DManual 26-102 MENU TREES

USER DISPLAY MODE

DAMPR

SETPT

INFO #

INQRY DG2

BATT AMPHR

LIGHT LTOFF

LT ON

PEAK

LCD

#

PK ON

PKOFF

8* Gauge will display either DG1 or DG2, dependent upon the current version.


Appendix D Digital Gauge I & II

MENU TREES Manual 26-102

CALIBRATION/SET-UP MODE

CAL A

M/D T

0-5 V

4-20

BRDGE

LOW ? # A/D L

HIGH? # A/D H

ENGR

MUL

MIN

MAX

DIV

DECML

OFSET

GAIN

#

#

#

#

#

#

#

LOW ? # A/D-L

ACAL

HIGH

#

# A/D-H TEST

HIGH?

FULL

TNG L #

HIGH

LOW

RMT LOCAL REMOT

LOW ? # A/D L


Digital Gauge I & II APPENDIX D

Manual 26-102 MENU TREES


CAL D MAX # MAX

RATIO #

DECML #

MIN #

RMT LOCAL

REMOT


Appendix D Digital Gauge I & IIMENU TREES Manual 26-102


CAL D ADCHN DSABL ANALG DIG 2

DIG 1

RTRPM

SPM 2

RPM

SPM

SPM 1

CALC

SETUP

SET I

A/D

NAME?

ERASE

REMOT

TEMP

ZROBT

SCALE

A/D

RPM

SET I

SNDR

TEMP

ZERO?

#

I ?

A/D

Gauge will display current viewed channel. Use the arrow keys to change channel name.

NONE RCR




CAL D ADCHN

DSABL

ANALG DIG 2

DIG 1

RTRPM

SPM 2

RPM

SPM

SPM 1

CALC

TMILE LINS?# ENGLS

METRC

F/PLS#




CAL D ADCHN

DSABL

ANALG DIG 2

DIG 1

T SPM

BITWT

STK12

STK 2

STK 1

CALC




CAL A ADCHN DSABL ANALG

DIG 2

DIG 1

L TEN

TTORQ

A TEN

HK/LD

CALC

PIT

RTORQ

MUDVL

FLOW

DIF P

TRP 1

PRESS

PMP P STK 1

DSABL

BITWT




APPENDIX ECALIBRATION AND SET-UP PROCEDURES

E-1 Introduction

This appendix contains the Digital Gauge (I & II) calibration and set-up engineering drawings. These drawing provide the details required when installing, calibrating, and configuring, the Digital Gauge system. You must reference these drawings while completing many of the procedures pro-vided in this manual.

E-2 List Of Drawings

The following Digital Gauge engineering drawings are located in this appendix:

Table E-1. List of Procudures

Drawing # Description # of Pages

221329-001 Sender/Receiver Configuration 3

221329-002 Calibrate Digital Gauge with MDT pressure sensor (221042-XXX) with no pressure applied to sensor

4

221329-003 Calibrate Digital Gauge with MDT pressure sensor (221042-XXX) with pressure applied to sensor

4

221329-004 Calibrate Digital Gauge with a voltage out-put sensor

3

221329-005 Calibrate Digital Gauge with a digital input sensor

3

221329-006 Procedure for analog calibration (4-20mA simulated)

4

221329-007 Procedure for analog calibration (4-20mA sensor

4

221370 Calibration for Digital Gauge I or II 5

August 14, 1997 Page E-1M/D TOTCO

Appendix E Digital Gauge I & IISYSTEM LEVEL DOCUMENTATION Manual 26-102

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APPENDIX FSYSTEM LEVEL DOCUMENTATION

F-1 Introduction

This appendix contains the Digital Gauge (I & II) System engineering drawings. These drawing provide the details required when installing, calibrating, configuring, and maintaining a Digital Gauge system. You must reference these drawings while completing many of the procedures pro-vided in this manual.

F-2 List Of Drawings

The following Digital Gauge engineering drawings are located in this appendix:

Table F-1. Drawings List

Drawing # Description # of Pages

221409 System Level Documentation 1

221372 Single Sensor (voltage) Interconnect 1

221386 Multi Sensor (voltage) Interconnect 1

221387 Single Sensor (4-20mA) Interconnect 1

221388 Single Sensor (4-20mA) Interconnect 1

221389 J-Box Wiring, Exane In/Exane Pressure Out 2

221390 J-Box Wiring, PVC In/ PVC Pressure Out 2

221391 J-Box Wiring, PVC In/ Exane Pressure Out 2

221392 J-Box Wiring, Exane In/ Exane 4-20MA Sensor

2

221393 J-Box Wiring, PVC In/ Exane 4-20MA Sensor

2

August 14, 1997 Page F-1M/D TOTCO

Appendix F Digital Gauge I & IISYSTEM LEVEL DOCUMENTATION Manual 26-102

Page F-2 August 14, 1997M/D TOTCO