DF9032 Thermal Exoansion Monitor Operation Guide

2019-09-18

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1.  /Overview

 

DF9032 dual channel thermal expansion monitor is a new product especially designed and manufactured for monitoring and protection of the thermal expansion of the shell of rotating machinery or valve location and travel, etc.

 

  • /True programmable instrument

 

The commissioning of DF9032 instrument no longer needs to open the instrument case, only using the mouse instead of a screwdriver; all the measuring parameter settings and instrument performance test can be easily completed by DF2900 configuration software!

 

DF2900 configuration software is the Windows Chinese interface which is simple and easy to operate.

 

  • /True maintenance-free instrument

 

The design and manufacture concept of monitoring-oriented special PLC ensures the high reliability of the instrument.

 

Built-in top grade microprocessor conducts continuous self-diagnosis on sensors, instrument circuits and software.

 

E2PROM automatically remembers the running data of instruments.

 

By the configuration of the instrument, the monitoring of thermal expansion or valve position or travel can be conveniently achieved.

 

Provide the difference value identification, change rate identification and other custom measurement functions to meet different needs.

Full range linearity compensation of the sensor.

 

Real-time record of measurement data can be easily downloaded for data analysis and troubleshooting.

 

2.  Description of the functions

 

  • DF9032 dual channel thermal expansion monitor can receive input signals from one or two LVDT sensor systems and continuously measure and monitor the thermal expansion or valve position and travel on the machine shell and provide mechanical protection for machinery.

 

  • DF9032 dual-channel thermal expansion monitor is an intelligent instrument based on top grade DSP processor.

 

Parameter setting is completed by DF2900 configuration software.

 

Normal observation operation can be accomplished through the instrument panel keyboard.

The following functions are provided in standard mode:

 

The programmable instrument functions are:

 

Two-channel independent operation: each channel independently measures, and two channels do not contact each other;

 

Two channels monitor the same parameter: Two channels monitor the same parameter, so high reliable measurement can be achieved and there is a difference identification function etc.;

 

Two-channel compensation measurement: one of two channels measures positive displacement, the other channel measures negative displacement, the two channel combination can measure the whole range of displacement;

 

Bevel measurements: measures bevel displacement and automatic slope compensation, and converted to thermal expansion.

 

Displacement measuring direction, compensation of bevel measurement and compensation of safety barrier are all programmable with automatic compensation calculation during the measurement;

The instrument provides DC power supply with over-voltage protection and short circuit protection for each sensor;

 

The sensor input signals after buffer processing are provided through the rear panel terminals (optional);

 

Warning, danger overrun identification and status indication, output of the monitoring value;

Each channel provides a programmable output voltage or current signal to the recorder, etc.;

 

The alarm control output logic of the instrument is programmable:

 

“Or” logic ─ ─ when overrun occurs in either channel, the relay will act;

 

“And” logic ─ ─ when overrun occurs in both channels, the relay will act;

 

 

The four control relay functions of the instrument are programmable, you can choose interlock switch-in or not switch-in, each relay can be configured as one (or both) channel OK, warning, positive warning, negative warning, danger, positive danger or negative danger functions as required; (This function is temporarily not available)

 

Instrument parameters and data are stored in the E2PROM, in case of power loss, they can be stored for long period.

 

DF9032 dual-channel thermal expansion monitor has comprehensive self-test and self-diagnosis functions:

 

The microprocessor regularly performs self-test on the instrument measuring circuit, depending on the running conditions of the measuring circuit of each channel of the instrument, when the circuit fails, it is automatically bypassed, then quit working;

 

The monitor has a circuit (OK Circuit) to monitor whether each sensor and its cable are working properly; when open (off) circuit or short circuit appears in a sensor coil, or the failure of abnormal preamplifier output occurs, it will automatically disable the danger control output of that channel so as to prevent the relay from malfunction causing the wrong shutdown of the unit;

 

Within wide range of the power supply input 165 ~ 265Vac, the instrument can operate highly reliably and highly stably. The instrument monitors the power supply, under the circumstances of power failure, power on, abnormal fluctuations etc., it can self-lock the operation status, bypass danger relay output; when the power is restored normally, it will continue to run as per the holding status.

 

  • In addition to the above standard functions, DF9032 dual-channel thermal expansion monitor particularly provides the following functions, which are elaborately designed for highly reliable monitor:

 

  • Sensor linear compensation:

 

By DF2900 configuration software, up to 20 segments of sensor data sheet can be inputted from the keyboard or automatically acquired. According to the data sheet, the instrument can correct the linearity on the sensor data.

Users can choose whether to correct the sensor linearity.

 

  • Difference value identification:

For more reliable monitoring, when two channels monitor the same displacement, and the difference between the two channels exceeds the limit, most likely the sensors or measuring circuit may have some failure; when the difference value overruns, the user can choose whether to send out warnings or lock the danger control output to prevent malfunction and provide more reliable protection to the unit.

 

  • Change rate identification:

Thermal expansion or the valve position and travel are generally slow variables. When abrupt change occurs, generally the sensor or measuring circuit will have fault, not the actual change of thermal expansion on the unit. When the rate of change is over the limit, the user can choose whether to send out warnings and lock the danger control output to prevent malfunction and provide more reliable protection to the unit.

(This function is temporarily not available)

 

3.  /Performances

 

▲ Standard tray-type desktop metal (or ABS plastics) case.

 

▲ABS panel frame, flexible film panel.

 

▲RS232 serial port for programming configuration;

 

Communication rate: 19200 bits/s.

 

▲ Power Supply: within 165 ~ 265Vac input power supply range, the instrument can operate stably;

 

Rated power consumption: 7.5 watts.

 

  • Signal input: switch in two channels of LVDT sensor input signals;

 

Provide excitation signals to the two-way sensor;

 

Signal source amplitude: 6Vp-p.

 

Signal source frequency: 1000Hz.

 

  • Measuring range: numerical programming, optional;

 

Measuring accuracy is better than ± 1% (full scale).

 

  • Display: Superbright red LED digital display;

 

Digital Display Accuracy: ± 1 digit.

 

  • Measuring frequency range: 0 ~ 10 Hz.

 

  • Record output: standard current and voltage both have output short circuit protection.

 

4 ~ 20 mA or (0 ~ 10 mA), load capacity ≮ 500Ω

 

1 ~ 5V or (0 ~ 10 V), current output ≮ 30mA.

 

  • Buffered sensor signal output: with short-circuit protection, output impedance 100Ω.

 

  • Relay: four set of relays, each relay has a set of contact output (normally closed, mid-point and normally open);

 

The relay output form is determined by software programming;

Contact output capacity: AC220V, 2A

 

  • Operating environment: Temperature: 0 ~ 55℃;

 

Relative humidity: lower than 95%, no condensation.

 

  • Panel size: 160mm × 80mm; Case Depth: 200 mm

 

  • Installation hole size: (151 ± 0.5) mm × (76 ± 0.5) mm

 

  • Mass: ≯2Kg

 

 

4.  /Panel description

 

 

4.1  /Data display

 

There are two display windows on the front panel of the instrument, each display window consists of four 0.5 superbright red nixie tubes.

 

When the instrument performs normal field monitoring work, the left window displays the monitoring result data of Channel A, and the right window displays the monitoring result data of Channel B.

 

During the operation of related function, the left window displays the function code and the right window displays the function data.

 

4.2  /Status indication

 

Below each display window of the instrument front panel, there are 6 LED indicator tubes in each window, which are used to indicate the nature of the digital display information, or the functions and alarms as follows:

 

 

4.2.1  LED under the display window

 

          

      

Power          LED on, indicating: instrument power failure;

LED off, indicating: instrument power supply is working properly;

 

Big difference     LED on, indicating: when Channel A and B monitor the same parameter, the difference of Channel A and B measuring results exceeds a set limit;

LED off, indicating: when Channel A and B monitor the same parameter, the difference of Channel A and B measuring results does not exceed a set limit;

 

OkA            LED on, indicating: Channel A sensor and measuring circuit are working properly;

LED off indicating: Channel A has following failure:

Sensor output signal is abnormal, generally open circuit and short circuit;

Instrument measuring circuit fails.

In this case, the instrument will appropriately bypass the danger relay or other control operations.

 

OkB          LED on, indicating: Channel B sensor and measuring circuit are working properly;

LED off, indicating: Channel B has following failure:

Sensor output signal is not normal, normally open circuit and short circuit;

Instrument measuring circuit fails.

In this case, the instrument will appropriately bypass the danger relay or other control operations.

 

A                LED on: indicating that Channel A (or B) measuring value exceeds the set alarm value;

 

D                LED on: indicating that Channel A (or B) measuring value exceeds the set danger value;

 

V              LED on, indicating that the number displayed in the window is the sensor output voltage, in unit of V;

 

mm            LED on, indicating that the number displayed in the window is the displacement value, in unit of mm;

 

4.3 Communication Interface

 

             t cable connection;

 

4.4 Key definitions

 

Press this key to clear the memory of the alarm condition of the instrument, reset relay and the “A”, “D” indicator lamps; if using two channels to monitor the same quantity, the indicator lamp “big difference” shall also be cleared.

 

 

    Two keys are pressed simultaneously, the instrument system will reset.

 

 

        

    Press this key, the instrument will switch over the following function displays in turn:

 

When the instrument operates normally, the display in the window of each channel is the measured displacement value of that channel, in unit of “mm”.

 

When the instrument measures normally, the display “-FFF” indicates that the input signal voltage is lower than the lower limit value of “OK”;

 

When the instrument measures normally, the display “FFF” indicates that the input signal voltage is higher than the upper limit value of “OK”;

 

When the above two displays occur, the corresponding channel OK lamp goes out.

 

When the instrument measures normally, the maximum value and minimum value displayed on the instrument corresponds to the upper limit and the lower limit of instrument measuring range.

 

   ;

        When the instrument operates on a specific function, enable the blinking numeric code to shift one digit leftward;

 

  When the instrument operates on a specific function, enable the numeric code of the corresponding digit to increase by 1;

 

When both keys are simultaneously pressed, each channel of the instrument takes the position at this time as the measuring zero point, the instrument will take sensor voltage of each channel measured at this time as a zero point voltage; the two-channel measured values are cleared to “0.00”.

(This function is temporarily not available)

 

 

5.  erminal connection on the rear panel

 

 

 

 

6.  Operational procedures of the instrument

 

Connect the terminals on the rear panel properly as described above.

 

Wiring Requirements:

 

▲ The connection of sensors to instrument better adopts the whole piece of three-core shielded cable, the middle of the cable shield must not be disconnected, and must not be wantonly connected to the ground or short-circuited with the chassis etc.; it shall maintain good insulation; when leading in the line contact bank, special shielding layer connecting terminal should be left on the other end.

 

The earth terminal of instrument AC power must be reliably connected to the earth;

 

▲ The sensor and instrument connection cables, AC power lines or other instrument strong current circuit cables are better not placed in parallel over long distance, particularly, they cannot be arranged in the same threading pipe;

▲ When the sensor is installed in the high power motor or generator, it is better to use non-metal support so that the sensor and case are insulated to reduce interferences;

 

▲ The instrument relay contact output is better used to control the intermediate relay, then the intermediate relay controls the load, not the relay within the instrument directly controls the load.

 

 

 

the specific relay output is shown in the left figure:

 

▲ The RS232 interface terminal on the rear panel is not explained temporarily, if required, we will otherwise provide you;

 

If the above installation requirements cannot be met, it may result in inaccurate measurement and unreliable control, we will not bear any responsibility.

 

2

Install [DF2900 configuration software] on the PC or portable computers. For installation instructions and software operating methods, see [DF2900 Configuration Software operating Guide].

 

3)

Connect one end of the serial cable provided with the software to the COM1 or COM2 serial port of a PC or portable computer, the computer is power on; and then plug the other end of the serial cable into the 6-core socket on the front panel of the instrument.

Switch on the power of the instrument, 8 nixie tubes and all the indicator lamps of the instrument are flashing for 10 seconds. If the self-test fails, then 8 nixie tubes and all indicator lamps are off. If the instrument passes the self-test, which means that it starts normal monitoring work, the left and right window respectively displays the axial displacement (or relative expansion value) in A, B Channels in the units of “mm”, then “mm” indicator lamp lights;

 

During the measurement, the instrument automatically monitor the power of various channels, if any kind of the power supply does not operate normally, the “power” lamp will light and automatically remove the danger relay; after the power returns to normal, it continues to work.

 

5)

If the instrument parameters are not set, run DF2900 configuration software, properly set up the parameters of instrument and download the parameters to the instrument through a serial cable, the instrument then resets and runs. You can also observe the instrument operation condition through DF2900 configuration software and conduct performance tests, etc.

 

Run [DF2900 configuration software] in the PC or desktop computer, DF9032 can set the following parameters:

 

☉ /Sensor parameters

 

Including: sensor type, specification and model selection;

 

Sensor output range, linear range and sensitivity setting;

 

Sensor linear correction function use, sensor linearity correction data sheet input or acquisition.

 

DF9032 thermal expansion monitor must adopt sensor linear correction, and switch in sensors to collect linear data point by point!

 

☉ /Instrument measuring parameters

 

Including: selection of the measuring functions of instrument channel and measuring combination form options:

 

Instrument measuring range and unit setting;

 

Input or acquisition of displacement zero voltage and displacement value;

 

Set the direction of displacement measurement;

 

Input of the compensation factors of bevel measurement and putting in safety barrier;

 

/Instrument output parameters

 

Including: Instrument standard output voltage and current selection;

 

Instrument alarm, danger combination control logic, difference monitor and control logic choice;

 

Function selection of the control relay;

 

Instrument alarm, danger limit, difference limit, action delay and the alarm hysteresis settings.

Serial communication rate setting.

 

Note: set the parameters properly when the instrument is not put in the field operation as possible;

 

If the instrument parameters are set during field operation, first use “Configuration ---- Test” mode to download parameters to the instrument, at this point each relay is locked (the contact is normally closed and the mid-point is connected) to prevent parameter setting error to cause relay misoperation.

Meanwhile, during the field operation, the time for setting the instrument parameters should be as short as possible so as not to affect the normal monitoring.

 

After the parameter setting is completed, the following operations can be performed by the software:

 

☉ Diagnosis of operation of the instrument;

 

☉ Simulation of the monitor display;

 

☉ Observe signal waveforms, and perform simple data processing and analysis;

 

☉ Read the instrument running record data.

 

7)

Unplug the serial connection cable and turn off the computer, the instrument can independently measure and monitor thermal expansion.

 

7 Key operation instructions:

 

Note: In order to correctly operate, when pressing the button, forcibly press it and hold for more than 1 second, release the button after conforming that the operation has been executed.

 

  • Inquire sensor voltage and setting

 

To achieve this by operating the “    ” button.

 

  • Functional operation

 

Functional operation can carry out some special operations on the instrument after the 4-digit password is correctly inputted, temporarily reserved for the manufacturer.

 

  • "Alarm Reset" operation

 

The instrument has alarm memory locking function: If the warning indicator lamp and relay memory lock are set, after the warning indicator lamp and the relay act, they will automatically lock the memory, even after the alarm condition is eliminated, it is still memorized, and alarm reset needs to be operated.

 

Implementation of the operation is to press the      button to clear the LED indicator lamp and relay related to alarm.

 

 

  • "system reset" operation

 

Implementation of the operation is to simultaneously press the   and     keys, the instrument will be reset and restart operation.

 

  • “零点采集”操作/“zero point acquisition” operation

 

In the on-site installation, corresponding to the mechanical zero position, the instrument indication shall correspondingly be zero; it is very difficult to achieve this requirement by adjusting the sensor probe position, so the simple way of the digital zero adjustment is arranged.

 

The operating method is to simultaneously press the      and   keys, the instrument will automatically collect zero point voltage and the indication of the instrument is cleared.

 

(This function is temporarily not available)