Cooper Instruments DFI-2000 Installation Manual

DFI 2000

Process Monitor and

Control Instrument

User’s Guide

www.cooperinstruments.com

PH: 540-349-4746 • FAX: [phone]

CONTENTS

1.0 INTRODUCTION ...................................................................................................................4

1.1 System Overview ........................................................................................................................... 4

1.2 Process Monitoring Functions ..................................................................................................... 4

1.3 The Process Control Output Signals ........................................................................................... 6

1.4 Programmable Setpoints............................................................................................................... 6

1.5 The Analog Output......................................................................................................................... 7

1.6 Data Logging .................................................................................................................................. 7

1.7 Automatic Calibration.................................................................................................................... 7

1.8 Absolute and Relative Modes ....................................................................................................... 7

1.9 Scaling ............................................................................................................................................ 7

1.10 Units .............................................................................................................................................. 8

1.11 Menu Locking............................................................................................................................... 8

1.12 Automatic Power-Down............................................................................................................... 8

1.13 Manual Power-Down.................................................................................................................... 8

1.14 AC Outlet or Battery Operation................................................................................................... 8

1.15 Support for Third Party Transducers ......................................................................................... 8

2.0 BASIC OPERATION .............................................................................................................9

2.1 Initial Power-up .............................................................................................................................. 9

2.2 Key Definitions............................................................................................................................... 9

2.3 The Menu System......................................................................................................................... 10

2.4 Using the Track Function............................................................................................................ 12

2.5 Using the Peak Functions ........................................................................................................... 13

2.6 Using the Auto and Manual Record Functions ......................................................................... 13

3.0 APPLICATIONS ..................................................................................................................14

3.1 Monitoring Continuous Change ................................................................................................. 14

3.2 Recording Peak Readings........................................................................................................... 14

3.3 Uploading Logged Peak Readings to a Computer or Printer .................................................. 15

3.4 Digitizing a Force-Time Curve .................................................................................................... 16

3.5 Using the Output Signals ............................................................................................................ 17

3.6 Programming Third Party Sensors.............................................................................................19

4.0 APPENDIX ..........................................................................................................................21

4.1 Connecting the DFI 2000 ............................................................................................................. 21

5.0 BATTERY REPLACEMENT................................................................................................ 22

5.1 Specifications............................................................................................................................... 22

6.0 WARRANTY REPAIR POLICY ...........................................................................................23

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1.0 INTRODUCTION

1.1 System Overview

The DFI 2000 is a multi-function Process Monitor and Control instrument, designed to operate with Cooper auto-id
transducers. The DFI 2000 has been enhanced to support torque sensors with quadature encoders. This
functionality is supported via AutoID and third party sensor programming. Version 7.2 will have an encoder chip and
new software installed. For easy verification of version 7.2, if a torque sensor with encoder is attached at power up,
an >E= will be displayed at the end of the line of the sensor data.

Additional features of the DFI 2000 are additional options under the menu items:

• Settings

• Transducer

The DFI 2000 is a portable instrument, and comes with the following:

• carrying case,

• shoulder strap,

• 12 V 600 mA power supply, and

• this manual.

If any of these items are missing, call Cooper Instruments at [phone].

Features
The DFI 2000 features:

• six process monitoring functions, including:

o a continuous tracking function,
o 3 peak logging functions,
o 2 waveform recording functions (with multiple record rates),

• 3 process control output signals (for High, Low and Target occurrences),

• programmable setpoints for Threshold, Target, High and Low Limits,

• analog output,

• storage capability for up to 8,000 peak readings,

• 4 [peak] data logging operations,

• automatic calibration with Cooper’s strain gage based auto-id sensors,

• collects absolute values or values relative to a user defined zero point,

• scaling adjustment for transducers,

• multiple unit capability and automatic units conversion,

• menu locking,

• automatic power-down,

• rechargeable Ni-Cad batteries, and

• support for third party transducers.

1.2 Process Monitoring Functions

The DFI 2000 provides six process monitoring functions:

• Track,

• - Peak,

• + Peak,

• +/- Peak,

• Auto Record, and

• Manual Record.

Track is always available by pressing the TRACK button. The FUNC button can be programmed for any one of the
other five functions.

Track
Track provides continuous monitoring of a process. The instrument takes readings at 5 kHz (without an encoder),
2kHz (with an encoder in >deg= mode), or 20Hz (with an encoder in >rpm= mode) averages them, and updates the

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display 4 times/second. In the Track function, re-taring zeros the encoder. (Track is designed for slowly changing
processes.)

Peak
The Peak functions (-, +, +/-) sample data at a rate of 5 kHz. However, if the encoder is enabled and in >deg=
mode, the sample rate is 2kHz. If the encoder is in >rpm= mode, the sample rate is 20 kHz.

In all Peak functions when readings drop below 80% of the user-defined Threshold Value, the PMAC engages a 100
msec timer. If readings rise above threshold within that time, the process cycle continues. If not, the process cycle
ends and readings are evaluated with respect to the limits. This timer is reset every time readings drop below
threshold.

Record
All functions except Manual record enable the encoder at the threshold for >deg= mode, or immediately for >rpm=
mode. Manual record enables the encoder at the manual trigger for >deg= mode. The Auto and Manual Record
functions have programmable record rates.

The >Record= functions will only allow 10kHz and 5kHz rates without an encoder. All other rates are allowed with an
encoder. The encoder is sampled at the record rate for Adeg@ or >rpm= mode.

The >Record= and Peak functions are limited to a total of 8,000 readings with or without an encoder.

+ Peak
+Peak collects, displays and evaluates the highest [positive] peak value above the user-defined threshold.

+ Peak ignores negative values.

-Peak

-Peak collects, displays and evaluates the lowest [negative] peak value below the user-defined threshold.

- Peak ignores positive values.

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+/- Peak
+/- Peak collects, displays and evaluates the greatest positive or negative values.

All setpoints are symmetrical about the x-axis.

Note: The DFI 2000 collects only one reading per process cycle. If readings rise from negative to positive values
within a process cycle, (this happens if readings are between the positive and negative Threshold for less than 100
msec.) the instrument records the peak with the greatest absolute value.

Auto and Manual Waveform Recording

Auto and Manual waveform recording are data recording functions that digitize incoming signals. Up to 16,000 data
points can be stored. Neither function displays readings, or evaluates them with regard to the limits. The following
update rates are available: 10, 5, 2, and 1 kHz, and 500, 200, 100, 50, 20, 10, 5, 2, and 1 Hz. For the 10 kHz*
scanning rate, data is sampled and stored; the instrument does not average the data. For the 5 kHz* scanning rate,
data is sampled at 5 kHz and continuously averaged to store readings. For each of the other scanning rates, data is
sampled at a rate of 6 kHz and continuously averaged to store readings at the selected rate.

*10kHz and 5kHz rates are only available when the encoder is not used.

1.3 The Process Control Output Signals

The DFI 2000 has three open collector, process control output signals:

• High Condition Signal,

• Low Condition Signal, and

• Target Signal.

When a Peak function is selected, the Target Signal is a real-time signal transmitted when a reading equal to, or
greater than, the Target Value is detected. The High Condition and Low Condition Signals are post-process signals
transmitted after readings drop below threshold, and the peak value is evaluated. These readings are also evaluated
with respect to the encoder limits and target value.

When Track is selected, all signals are transmitted in real-time. When a waveform recording function is selected, all
signals are disabled.

All three signals are TTL compatible and are transmitted through the I/O connector on the back of the unit. (See the
chapter on Connecting the PMAC for more information.)

1.4 Programmable Setpoints

When each type of sensor (i.e., force, torque or displacement) is first connected to the DFI, the instrument sets all of
the setpoints to their default values.
Threshold Value = 5% of sensor's Full Scale

High Limit = sensor's Full Scale
Low Limit = 5% of sensor's Full Scale

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Target Value = sensor's Full Scale

Each of these values may be changed by the operator. (See the Basic Operation and Applications chapters.) The
DFI 2000 retains the most recent setpoint values for all three types of sensors; i.e., when you disconnect a torque
sensor and connect a force sensor, the setpoints are reset to the values used with the last force sensor connected
to the instrument.

1.5 The Analog Output

The analog output is the signal from the transducer, amplified and relayed through a low pass filter. The instrument
provides an excitation of 7 V. The amplifier has a gain factor of 76 for a nominal output of 1 V at 2 mV/V. This signal
is transmitted through the I/O connector. (See the Appendix for wiring diagrams.)

1.6 Data Logging

The peak functions log all peak values automatically. The DFI 2000 provides for:

• viewing [peak] readings on the DFI 2000 screen (one at a time),

• uploading the readings to a PC

• transmitting the readings directly to a serial printer, or

• erasing the readings.

The DFI 2000 can store up to 8,000 [maximum] peak readings.

Note: The data is stored in blocks, and each block contains a header. Each time you change transducer types or
units, the instrument must store an additional heading which reduces the memory available for storing peak values.
Leaving a waveform stored in memory will also reduce the memory available for storing peak values.
No data logging occurs when the Track or waveform recording functions are selected. Data collected by the
waveform recording functions must be uploaded to a PC or erased. It can not be viewed on the DFI 2000 screen.

Data Transmission
The DFI 2000 transmits data in ASCII format with the following parameters:
Baud Rate = 9600
Parity = None
Data Bits = 8
Stop Bits = 1
Flow Control = None or Xon/Xoff

1.7 Automatic Calibration

The DFI 2000 is designed to support Cooper’s auto-id sensors. Cooper’s auto-id sensors are equipped with an
EPROM that stores the sensor's Full Scale value, the mV/V output, and engineering units. The DFI 2000
automatically reads these values when:

• the sensor is initially connected,

• when the instrument is powered up, and

• when the operator exits the menu structure.

The DFI 2000 automatically recalibrates to the sensor when it detects a change in these values.

1.8 Absolute and Relative Modes

The DFI 2000 uses an internal reference bridge to define absolute zero. In Absolute mode, readings are taken with
respect to this value. In Relative mode readings are taken with respect to a tare value from the transducer.

Important: When using Absolute mode, it is important that the user-defined threshold be at least 25% greater than
sensor's offset from zero.

1.9 Scaling

The DFI 2000 multiplies all new readings by the scaling factor before storing or displaying the data. Changing the

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scale factor does not affect previously stored readings. With a scale factor of 1.0 the instrument stores and displays
readings exactly as taken.

The instrument retains the most recent scale factor for all three types of sensors. (Same as the setpoints for the limit
values.)

1.10 Units

The DFI 2000 provides automatic unit conversion. The Full Scale value for all Cooper’s auto-id sensors are
specified in engineering units. When the operator selects a different set of units, the DFI 2000 converts the Full
Scale value, the High and Low limits, the Threshold and Target values, and all readings [taken from that point on] to
the new units. The following units are available:
Force: oz, lbs, Tons, g, kg, N
Torque: inoz, inlbs, ftlbs, kgcm, kgm, NM
Displacement: mils, in, mm, cm
Absolute numbers: None

Note: The DFI 2000 will only allow the operator to select units that are consistent with the type of transducer
connected, i.e., torque units for a torque transducer.

1.11 Menu Locking

All of the above mentioned features are accessed through the DFI 2000's menu system. Each of the four menus
(see the Basic Operations chapter) can be locked to prevent accidental changes.

1.12 Automatic Power-Down

The DFI 2000 will automatically power-down 12 minutes after the transducer is disconnected (unless the instrument
is in the menu system).

1.13 Manual Power-Down

To power-down the instrument manually, hold the OFF key for five seconds and release.

1.14 AC Outlet or Battery Operation

The DFI 2000 can operate from an AC outlet or from the internal Ni-Cad batteries. When completely charged, the
batteries should last for approx. 8 hrs.

To completely charge the batteries, the instrument must be plugged into an outlet for 16 hrs. There is no danger of
over-charging the batteries if left plugged in for longer than 16 hrs.

Note: If the instrument is left charging for "several weeks", the batteries' charge life will be severely diminished. (This
is a property of all Ni-Cad rechargeable batteries.) Cooper recommends completely discharging the batteries on
occasion to maintain their charge life.

Note: When shipped from Cooper’s factory, the batteries will be completely discharged.

1.15 Support for Third Party Transducers

Third party transducers may be connected to the DFI 2000 using a standard 15 pin D-sub connector, or Cooper’s
auto-id connector (Model 90144). In either case, when the sensor is first connected to the DFI 2000, the instrument
will prompt you for the sensor's calibration data. (See the Applications chapter).

When using sensors with a standard 15 pin connector, the data is stored in RAM. So that it is not necessary to
reenter the calibration data if the sensor is disconnected and immediately reconnected. But it must be reentered if
another sensor is connected in the interim. These sensors are identified as "Raw".

When using sensors with Cooper's auto-id connector, the instrument writes the calibration data to the connector's

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