Cooper Instruments DFI-2555 Installation Manual
DFI 2555
MEASURING AMPLIFIER
USER’S GUIDE
www.cooperinstruments.com
PH: 540-349-4746 • FAX: 540-347-4755
CONTENTS
SAFETY INSTRUCTIONS............................................................................................................1
1.0 INTRODUCTION ....................................................................................................................2
1.1 Scope of supply ..............................................................................................................................2
1.2 General............................................................................................................................................. 2
1.3 Block diagram .................................................................................................................................3
2.0 MOUNTING ............................................................................................................................3
2.1 Pre-installation notes, factory settings......................................................................................... 3
2.2 Changing the factory settings .......................................................................................................3
2.2.1 Setting the analog output signal.............................................................................................4
2.2.2 Choosing the operating mode for synchronization .............................................................. 4
2.2.3 Replacing the fuses .................................................................................................................4
2.3 Installing the amplifier in a panel-frame .......................................................................................4
3.0 CONNECTIONS .....................................................................................................................4
3.1 Connecting the voltage supply...................................................................................................... 4
3.2 Connecting transducers................................................................................................................. 5
3.3 Analog output.................................................................................................................................. 6
3.4 Control inputs / outputs .................................................................................................................6
3.5 Synchronization .............................................................................................................................. 7
3.6 Setting the reading angle of the display.......................................................................................7
3.7 Connecting the serial interface......................................................................................................8
4.0 SETTING UP AND OPERATION ...........................................................................................8
4.1 Commissioning and factory settings............................................................................................8
4.2 Control concept and functional overview...................................................................................12
4.3 Button functions in measuring mode .........................................................................................13
4.3.1 Querying and setting limit values in measuring mode.......................................................13
4.4 Button functions in programming mode ....................................................................................14
4.4.1 Changing from ”Measuring” Operating Mode to ”Programming” ....................................14
4.4.2 Programming..........................................................................................................................14
4.4.3 Switching from ”Programming” Mode to ”Measuring” ...................................................... 15
4.5 Overview of all groups and parameters......................................................................................15
4.5.1 Setting all parameters............................................................................................................ 16
4.5.2 Dialogue .................................................................................................................................. 19
4.5.3 Load/Save in parameter set (PARAM. SET) ......................................................................... 19
4.5.4 Adaptation...............................................................................................................................19
4.5.5 Calibration (CALIBR.).............................................................................................................21
4.5.6 Limit switches 1 ... 4 (LIMITVAL.1 ... 4).................................................................................22
4.5.7 Set peak value store (PV STORE) ......................................................................................... 23
4.5.8 Inputs and outputs (IN/OUT) .................................................................................................24
4.5.9 Additional functions (ADD. FUNCT) .....................................................................................25
5.0 EXAMPLE ............................................................................................................................27
6.0 ERROR MESSAGES ...........................................................................................................32
7.0 SPECIFICATIONS................................................................................................................32
8.0 WARRANTY REPAIR POLICY ............................................................................................36
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SAFETY INSTRUCTIONS
To ensure safe operation, the device may only be operated in accordance with the information given in the Operating Manual. It is also essential to comply with the legal and safety requirements for the application concerned during use. The same applies to the use of accessories.
Before commissioning, find out whether the mains voltage and current type specified on the identification plate
match the mains voltage and current type at the place of use, and whether the circuit being used is adequately protected.
Built-in devices must only be operated while they are within the housing provided for them.
The device complies with the safety requirements of DIN EN 61010-Part 1 (VDE 0411-Part 1); Protection Class I.
As the device does not have a separate power switch, do not apply the power cable directly to the mains.
According to the VDE guideline, there must be a switching device to disconnect the device from the mains.
Use in accordance with the regulations
The DFI 2555 with connected transducers is only to be used for measurement tasks and directly associated control
functions. Use for any purpose other than the above shall be deemed to be not in accordance with the regulations.
General dangers due to non-observance of the safety instructions
The DFI 2555 is a state-of-the-art device and is fail-safe. The device may give rise to further dangers if it is inappropriately installed and operated by untrained personnel. Any person instructed to carry out installation, commissioning, maintenance or repair of the device must have read and understood the Operating Manual and in particular
the technical safety instructions.
Remaining dangers
The scope of supply and list of components provided with the DFI 2555 cover only part of the scope of measurement technique. In addition, equipment planners, installers and operators should plan, implement and respond to
the safety engineering considerations of measurement technique in such a way as to minimize remaining dangers.
Prevailing regulations must be complied with at all times. There must be reference to the remaining dangers connected with measurement technique.
In this manual, the remaining dangers are indicated by the following symbols:
Symbol:
Meaning: Maximum danger level
Warns of a decidedly dangerous situation in which failure to comply with safety requirements will lead to death or
serious physical injury.
Symbol:
Meaning: Dangerous situation
Warns of a potentially dangerous situation in which failure to comply with safety requirements can lead to death or
serious physical injury.
Symbol:
Meaning: Potentially dangerous situation
Warns of a possibly dangerous situation in which failure to comply with safety requirements could cause damage
to property or result in some kind of minor physical injury.
Symbols for using advices and helpful information:
Symbol:
Means that important information about the product or its handling is being given.
Symbol:
Meaning: CE mark
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DANGER
WARNING
CAUTION
NOTE
The CE mark enables the manufacturer to guarantee that the product complies with the requirements of the relevant EC directives.
Working safely
Error messages must only be acknowledged when the cause of the error has been removed and no further danger
exists.
Conversions and modifications
The DFI 2555 must not be modified from the design or safety engineering point of view except with our express
agreement. Any modification shall exclude all liability on our part for any resulting damage. In particular, any repair
or soldering work on motherboards is prohibited (this includes changing components other than EPROMs). When
exchanging complete modules, use only original parts from Cooper.
Qualified personnel
This instrument must only to be installed and used by qualified personnel, strictly in accordance with the technical
data and the safety requirements and regulations listed below. It is also essential to comply with the legal and
safety requirements for the application concerned during use. The same applies to the use of accessories. Qualified personnel means persons entrusted with the installation, assembly, commissioning and operation of the product that possess the appropriate qualifications for their function.
1.0 INTRODUCTION
1.1 Scope of supply
• Device with front frame
• 2 fastening straps
• One male cable connector DB-15P
• One 3-pin terminal strip connector (mains connection)
• One 3-pin terminal strip connector (interface)
• Two 9-pin terminal strip connectors (control inputs/outputs)
• Operating Manual and Serial Communications Guide for RS232/485.
1.2 General
The panel-frame measuring amplifier DFI 2555 for instrument panel mounting (in accordance with DIN43700) is
suitable for recording and processing measured values from passive transducers in the industrial test bench engineering sector and for monitoring production processes.
The essential features:
• Transducers that can be connected: S.G. full and half bridges, inductive full and half bridges, piezoresistive and
potentiometric transducers, LVDT
• 10-digit alphanumeric display
• Touch-sensitive keypad control; individual buttons can be locked
• Two peak value stores for maximum and minimum values, as well as envelope and instantaneous value
• Four limit switches
• RS232 or RS485 serial interface for connecting a computer or a printer
• Parameter memory for saving up to 8 data sets
• Control inputs and outputs (potential-separated through optical couplers)
• The DFI 2555-RS485 version can be operated together with other DFI 2555s (at a common RS485 bus)
All the commands needed for device setup over the serial interface and for querying the measured values are listed
and described in a separate manual, “DFI 2555 Serial Communications Guide”.
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1.3 Block diagram
Fig. 1.1 DFI 2555 block diagram
2.0 MOUNTING
2.1 Pre-installation notes, factory settings
Before installing the device, check the parameters set at the factory, as the elements for selecting the analog output
signal (current/voltage output) and for setting synchronization, are located on the motherboard.
The factory settings are given below:
• Mains voltage: 230 V / 50 ... 60 Hz or 115 V / 50 ... 60 Hz, depending on order
• Analog output: output voltage ±10 V
• Synchronization: Master
Fig. 2.1: Location of jumpers on motherboard
2.2 Changing the factory settings
To change the factory settings, proceed as follows:
• Loosen the four screws at the back of the housing.
• Carefully extract the back panel of the housing backward, with the motherboard attached, until the jumper ar-
rangement is accessible. You can place a screwdriver between the connection board and the housing and lever
out the back panel.
• By following the diagram, change whichever setting is relevant to you with the aid of the jumpers.
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2.2.1 Setting the analog output signal
To make the analog output signal setting (voltage or current), use jumpers ST11. Choose between ±20 mA or 4 ...
20 mA in the control dialogue.
2.2.2 Choosing the operating mode for synchronization
To synchronize several devices, set one device as the Master. All the other devices should then set to Slave. To
make the “Master” and “Slave” selections, use jumpers ST13, ST14 and ST15.
2.2.3 Replacing the fuses
To replace the fuse, remove the back panel of the housing as described. The fuse (230 V/100 mA; 115 V/200 mA)
will then be accessible on the motherboard (see Fig. 2.1).
2.3 Installing the amplifier in a panel-frame
The DFI 2555 is designed to be installed in panel-frames, in accordance with DIN43700.
Installation steps:
• Remove the fastening strap.
• Insert the housing into the cutout in the panel-frame from the front.
• Hang up the fastening strap on both sides and fasten it to the cutout with the two threaded rods.
• Then connect the supply voltage and the transducer, as shown in chapter 3.
Fig. 2.2: Housing with fastening components
3.0 CONNECTIONS
CAUTION
Before commissioning the device, please observe the safety instructions.
3.1 Connecting the voltage supply
Check that the mains voltage of the device (details on the back of the device) matches the supply voltage. If this is
not the case, please contact Cooper Instruments.
Fig. 3.1 Back of the device
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CAUTION
As the device does not have a separate power switch, do not connect the power cable directly to the
mains. According to the VDE guideline, there must be a switching device to disconnect the device from the
mains.
Connecting the mains cable:
• The cable must not be connected to the mains!
• Twist the wire ends of the mains cable and fit the end sleeves for strands
• Screw the wire ends to the terminal strip connector (3-pin)
Fig. 3.2: Pin assignment of the terminal strip connector (3-pin)
• Plug the terminal strip connector (3-pin) into the mains connection socket
3.2 Connecting transducers
The following transducer types can be connected to the device:
• S.G. full and half bridge transducers
• Inductive full and half bridge transducers
• Potentiometric and piezoresistive transducers
• LVDT (Linear Variable Differential Transformer)
The connection is made using a 15-pin D-Sub connector on the back panel of the housing, labeled BU1 (cable end
connector: DB-15P).
Fig. 3.3: Connecting different transducers
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When connecting a transducer using four-wire technique, you must connect the sensor circuits with the relevant
bridge excitation circuit in the male cable connector (pin 5 with pin 12 and pin 6 with pin 13).
Fig. 3.4: Transducer connection in four-wire technique
NOTE:
To connect the transducers, use standard cable. If you use another shielded, low-capacitance
measurement cables, connect the shielding of the transducer cable to the connector housing, in accordance with HBM Greenline information (document G36.35.0). This guarantees EMC protection.
3.3 Analog output
The analog output signal is available as voltage (±10 V) or as current (±20 mA or 4 ... 20 mA) at terminals 1 and 2.
To choose current or voltage, use the jumpers on the amplifier motherboard, as described in Chapter 2.1.
Pin Function Pin Function
1 Output signal (V/I) 10 no function
2 Output signal (ground) 11 Synchronization (+)
3 LIMITVAL.1 12 Synchronization (-)
4 LIMITVAL.2 13 Remote1 (...)
5 LIMITVAL.3 14 Remote2 (...)
6 LIMITVAL.4 15 Remote3 (...)
7 Warning 16 Remote4 (...)
8 Ground 17 Remote5 (...)
9 External supply voltage 24 V= 18 Remote6 (...)
Fig. 3.5: Output pin assignment
3.4 Control inputs / outputs
Input/Output Terminal Function
←
←
←
←
←
→
→
→
3 Output LIMITVAL. 1
4 Output LIMITVAL. 2
5 Output LIMITVAL. 3
6 Output LIMITVAL. 4
7 Output warning (overflow) Warning active in the case of overflow,
8 Ground V
9 External supply voltage V
13-17 Input remote 1-6 (function
selectable)
With positive logic equivalent to V
24 V
Autocal and MOTION OUT
24 V =OK
0 V = Warning
0 V
ext.
24 V
ext.
see table on Page 46
ext.
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DFI 2555
Fig. 3.6: Output assignments
The control inputs and outputs are available at the terminal strip socket (9-pin) and are potential-separated by optical couplers.
* The control outputs and inputs must be supplied with an external voltage (ground and 24 V).
NOTE
When the mains voltage is disconnected or fails and when the mains fuse blows, all the control outputs are
set to 0 V (V
ext.
).
3.5 Synchronization
If several devices are used right next to one another or if their cables run parallel, the devices should be synchronized. To achieve this, one device is set to Master and all the others (max. seven) to Slave. The setup with jumpers
on the amplifier motherboard is described in Chapter 2.1. As well as these settings, the devices must be linked together for synchronization.
Fig. 3.7: Terminal connections for synchronization
3.6 Setting the reading angle of the display
Depending on the mounting position, it may be possible to adjust the reading angle. A potentiometer is used for this
limited adjustment. The potentiometer is located behind the keyboard under the display. To set a new viewing angle, proceed as follows:
• Remove the plastic frame of the display from the housing.
• Carefully lever out the keyboard (e.g. with the aid of a screwdriver).
• Use a screwdriver to turn the potentiometer and set the optimum reading angle.
• Put back the keyboard. Make sure that the plug is correctly threaded at the bottom edge of the keyboard.
Quickly test the keyboard by pressing a key. If it functions correctly, you can continue.
• Insert and tighten the fastening screws.
• Push the plastic frame back on the housing.
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3.7 Connecting the serial interface
PK232-interface:
On the back of the device, there is an RS232 or RS485 serial interface for connecting a computer or
a terminal. The PK485-interface is brought out at sockets Bu2 and Bu3.
When connecting a printer, a simple line printer needing no more than 4 seconds to print a line is
sufficient. The printout has 12 columns. This corresponds to a line length of 132 characters. Select
the measured values to be printed as described in Chapter 4.4.11.
When connecting a computer, it is possible to enter into dialogue with the DFI 2555. You can use control commands to make all the device settings and query the measured values. An overview of the interface commands has
been compiled in another Operating Manual “DFI 2555 Serial Communications Guide”.
4.0 SETTING UP AND OPERATION
4.1 Commissioning and factory settings
Some of the steps you need to take to commission your measurement chain (panel-frame amplifier and transducer)
are listed below, so that you can carry out an initial function test of all components. The description basically covers
adapting the DFI 2555 to the transducer type to be used. We also warn about certain errors that can typically occur
during commissioning.
• Follow the steps given in the previous chapter to connect the mains cable and the transducer to the measuring
amplifier.
Please observe the safety instructions!
• Turn on the power switch.
• The device runs a function test and is then in measuring mode. Duration of the function test: 1.5 s (if auto-
calibration is enabled, approx. 2.5 s). During the function test, the warning output stays at 0 V. The factory
settings are active.
• Check the choice of output signal shown on the display. Use
display).
to select the gross signal (no labeling in the
NOTE
If the error message CALERR. appears here, this can have the following causes:
- No six-wire feedback connected
- Incorrect transducer/sensor connection
- No transducer/sensor connected
Remedy:
Switch off the device. Connect the transducer properly. Switch the device back on.
NOTE
If the error message “OVFL B, OVFL N,” appears, you must adjust the amplifier for your type of transducer. The
steps to take for each amplifier are described below.
• To get from measuring mode to device setup mode, press
play.
• Follow the examples given below to adjust the device to the connected transducer type.
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for about 2 s. ”DIALOG” will appear in the dis-
Transducer types:
S.G. force transducer:
Adaptation:
Example
Transducer type: Full bridge/2 mV/V=20 kN
Excitation: 2.5 V
Input: 4 mV/V
Calibration Unit, nominal value/decimal point 20.000 kN
Measuring range 2 mV/V
Inductive displacement transducer:
Adaptation:
Example
Transducer type: Half bridge, 10 mV/V
(80 mV/V)
Excitation: 1.0 V
Input: 10 mV/V (100 mV/V)
Calibration: Unit, nominal value/decimal point: 20.000 mm
Measuring range: 10 mV/V (80 mV/V)
Piezoresistive transducer:
Adaptation:
Example
Transducer type: Half bridge
Excitation: 2.5 V
Input: 400 mV/V
Calibration: Unit, nominal value/decimal point: 30.000 bar
Measuring range: 200 mV/V
Potentiometric transducer:
Adaptation:
Example
Transducer type: Half bridge
Excitation: 1 V
Input: 1000 mV/V
Calibration: Unit, nominal value/decimal point: 10.000 mm
Measuring range: 1000 mV/V
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