MD Totco Series 2000 Instruments Installation, Calibration, & Operation

Series 2000 Instruments
Installation, Calibration, and Operation

4-20mA Input
Single Axis Line Tension, Payout, and
Speed
REFERENCE REFERENCE DESCRIPTION
This document contains proprietary and confidential information which NOV M/D Totco
belongs to National-Oilwell Varco, L.P., its affiliates or subsidiaries (all
collectively referred to hereinafter as "NOV"). It is loaned for limited 1200 Cypress Creek Road
purposes only and remains the property of NOV. Reproduction, in whole Cedar Park, Texas 78613
or in part, or use of this design or distribution of this information to others
is not permitted without the express written consent of NOV. This
USA
document is to be returned to NOV upon request and in any event upon Phone 512-340-5000
completion of the use for which it was loaned. This document and the Fax 512-340-5219
information contained and represented herein is the copyrighted property
of NOV.
© National Oilwell Varco
DOCUMENT NUMBER REV
90-01 E
www.nov.com/mdtotco
Document number 90-01
Revision E
Page 1 of 158
Revision History
E 04.17.2007 Revised per EC #: 69784-01

01.07.2007 NOV Template Conversion
D 10.03.2000 Released per EC #: 49065
B 11.12.1997 Released
A 08.31.1999 Initial Release
Rev Date Reason for issue Prepared Checked Approved
Change Description
Revision Change Description

A First Issue
B Revision
D Revision
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Revision E
Page 3 of 158
Table of Contents
Chapter 1: General Information
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 2: Overview
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LM2000 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Sensor Excitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Aux Comm (Half-duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Industry standard plug-in relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Back Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 3: Installation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Mounting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Standard Panel Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Dashmount Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Heavy Duty Stainless Steel Bezel Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remote Data Acquisition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wire Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TB1-12/24VDC (Power Input) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TB2-PWR OUT (Power Output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
TB3-RS485 (Network Communication) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TB4-ANLG1 (Analog Input #1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TB5-ANLG2 (Not Used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
TB6-ANLG3 (Not Used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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TB7-ANLG4 (Not Used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
TB8-POS PWR (Payout Sensor Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
+5 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
+24 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
+12 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
TB9-POS SIG (Payout Sensor Signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
TTL (0 to +5 VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Open Collector (NPN) Sinking (Switch to Ground) . . . . . . . . . . . . . . . . . . . . . . . . . .26
Open Collector (PNP) Sourcing (Switch to +24 VDC) . . . . . . . . . . . . . . . . . . . . . . .27
NAMUR (Proximity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
TB10 Through TB13 (Relay Option Terminal Blocks) . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Terminal Blocks for Analog Output/Aux Comm Option Modules 1 to 4 . . . . . . . . . . . . .29
Analog Output Option Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Aux Comm Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Even Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Chapter 4: Normal Operation

Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Navigation Routes From the Operator’s Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
How to Navigate Through Screens and Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Keypad Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Label Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Menu Label Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Item Label Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Data Entry Label Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
ACK Label Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Keypad Labels on the Operator’s Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
ACK (Acknowledge Alarms) Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Using the ACK key to Silence a Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Using the Ack Key to Clear All Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Payout Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Zeroing an Existing Payout Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Entering a Preset Payout Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
CAL Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Verifying Tension-Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Entering Numbers Into the Scratch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Screen Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Using the Screen Menu to Select a Screen Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Screen Menu Layout Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
3 Bar Graphs Operator’s Screen Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Digital Tension Operator’s Screen Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Digital Payout Operator’s Screen Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
2 Bar Graphs, Payout/Speed Operator’s Screen Layout . . . . . . . . . . . . . . . . . . . . .44
Big Bar Graph, Tension Operator’s Screen Layout . . . . . . . . . . . . . . . . . . . . . . . . .44
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Big Bar Graph, Payout Operator’s Screen Layout . . . . . . . . . . . . . . . . . . . . . . . . . 45
Menu Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Chapter 5: Configuration and Calibration

Menus and Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Alarm Setpoints Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Entering Alarm Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Display Adjust Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Adjusting Display Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Adjusting the Backlight Brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Adjusting the Backlight Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Adjusting the Slow Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Graph Scales Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Entering Graph Scale Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Calibration Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Cal Check Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Verifying Tension-Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Entering Numbers Into the Scratch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Two Point Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Physical Load Calibration for Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Shunt Calibration (Remote Calibration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Voltage Substitution Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Data Calibration Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Payout Calibration Using Data Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Calculating Payout Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Payout Calibration Using Two-Point Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Analog-Output Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
System Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Operator Privileges Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Units of Measure Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Relay Setup Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Alarm Assignments Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Relay Type Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Network Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Configuring the Instrument as a Sensor Input Unit . . . . . . . . . . . . . . . . . . . . . . . . . 72
Configuring the Instrument as a Remote Display Unit . . . . . . . . . . . . . . . . . . . . . . 73
Aux. Comm. Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Chapter 6: Troubleshooting
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Navigating the Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Diagnostic Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Raw Counts (troubleshooting diagnostic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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Power Supplies (run time background) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Error Logs (troubleshooting diagnostic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Local (or Sensor) Network Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Local (or Sensor) Hardware Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Self Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Self Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Perform Self Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Load Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Relays-Alarms Disabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Options (troubleshooting diagnostic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
SPI Diagnostics (run-time background) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Software Update Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Error Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Appendix A: Glossary
Appendix B: Alarms and Relays

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Relay Contact Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Normally Open Contacts vs. Normally Closed Contacts . . . . . . . . . . . . . . . . . . . . . . . . .93
Mechanical Contacts vs. Solid State Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Horn vs. Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Fail-safe vs. De-energized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Horn Relay vs. General-Purpose Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Latched vs. Unlatched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Cal Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Alarm Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Alarm and Relay Programming via the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Alarm Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Relay Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Tips and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Appendix C: Strain Gauge Sensor Calibration

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Physical Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Physical Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Shunt Calibration (Shuntcal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Shuntcal Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Voltage Substitution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Voltage Substitution Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Bridge Substitution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Routine Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
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Product Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Appendix D: Load Cell Troubleshooting

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Excitation Voltage Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Load Cell Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Bridge Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Insulation Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Interconnect Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Troubleshooting Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Insulation Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Cable Insulation Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Bridge Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Excitation Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Signal Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Troubleshooting Field Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Appendix E: Option Modules

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Analog Output Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Aux Comm Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Even Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Appendix F: Auxillary Communications

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Protocol Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Command List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Delimiter Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Protocol # 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
SS Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
CS Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
CD Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Protocol # 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
CD Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
SS Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
CS Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
AK Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
C1 Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
C2 Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
RS Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
ST Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
RT Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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Aux Comm Response Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
SS (single scan) Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
C1 (Cal1) Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
CD (Configuration Dump) Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Conclusions on Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Appendix G: Networking
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Sensor Input Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Sensor Input Unit With Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Sensor Input Unit Without Display (DAQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Remote Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Sensor Input Unit Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Remote Display Unit Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Network Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Network #1—Remote DAQ to Remote Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Network #2—Sensor/Display to Remote Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Network #3—DAQ to Multiple Remote Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Network #4—Sensor/Display to Multiple Remote Displays . . . . . . . . . . . . . . . . . . . . .135
Network #5—Remote Display to Multiple DAQs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Network #6—Remote Display to Multiple Sensor/Displays . . . . . . . . . . . . . . . . . . . . .137
Network #7—Multiple Remote DAQs to Multiple Remote Displays . . . . . . . . . . . . . . .138
Network #8—Multiple Sensor/Display Units to Multiple Remote Displays . . . . . . . . . .139
Networking and Aux Comm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Network/Aux Comm Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Network #9—Multi. Sensor/Display to Multi. Remote Displays w/ Aux Comm . . . . . . .140
Network #10—Multi. Sensor/Display w/ Aux Comm to Multi. Remote Displays . . . . . .142
Appendix H: Interconnect Example Drawings

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Appendix I: Illustrated Parts Lists

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Locating Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Model Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
What Type of LM2000 is it? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
What Kind of Enclosure? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Which Relays are Installed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
What Option Modules are Present? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
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1: General Information
This manual contains installation, operation, maintenance and parts information. Information in this
manual should enable qualified personnel to install, operate and troubleshoot this system. Every
effort has been made to ensure the accuracy of the information contained herein. National Oilwell
Varco’s M/D Totco, will not be held liable for errors in this material, or for consequences arising
from misuse of this material.
Conventions
Notes, Cautions, and War nings
Notes, cautions, and warnings provide readers with additional information and advise the reader to
take specific action to protect personnel from potential injury or lethal conditions. They may also
inform the reader of actions necessary to prevent equipment damage. Please pay close attention
to these advisories
Note: The note symbol indicates that additional information is provided about the
current topics.
Caution: The caution symbol indicates that potential damage to equipment or injury to
personnel exists. Follow instructions explicitly. Extreme care should be taken
when performing operations or procedures preceded by this caution symbol.
Warning: The warning symbol indicates a definite risk of equipment damage or
danger to personnel. Failure to observe and follow proper procedures
could result in serious or fatal injury to personnel, significant property
loss, or significant equipment damage.
ESD The ESD (Electrostatic Discharge) warning symbol indicates that static
Warning: control precautions are needed.
Illustrations
Illustrations (figures) provide a graphical representation of equipment components or screen
snapshots for use in identifying parts or establishing nomenclature, and may or may not be drawn
to scale.
For component information specific to your application, see the technical drawings included with
your M/D Totco documentation.
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Safety Requirements
M/D Totco equipment is installed and operated in a controlled drilling rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation. Procedures
outlined in M/D Totco manuals are the recommended methods of performing operations and
maintenance.
To avoid injury to personnel or equipment damage, carefully observe requirements outlined

in this section.
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the
equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool operation,
and maintenance to ensure their safety.
Personnel should wear protective gear during installation, maintenance, and certain
operations.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose described.
M/D Totco recommends that only those tools specified be used when stated. Ensure that
personnel and equipment safety are not jeopardized when following service procedures or using
tools not specifically recommended by M/D Totco.
General System Safety Practices

The equipment discussed in this manual may require or contain one or more utilities, such as
electrical, hydraulic, pneumatic, or cooling water.
Read and follow the guidelines below before installing equipment or performing
maintenance to avoid endangering exposed persons or damaging equipment.
Isolate energy sources before beginning work.

Avoid performing maintenance or repairs while the equipment is in operation.
Wear proper protective equipment during equipment installation, maintenance, or repair.
Replacing Components
Verify that all components (such as cables, hoses, etc.) are tagged and labeled during
assembly and disassembly of equipment to ensure correct installment.
Replace failed or damaged components with genuine M/D Totco parts. Failure to do so
could result in equipment damage or injury to personnel.
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Routine Maintenance
Equipment must be maintained on a routine basis. See the service manual for maintenance
recommendations.
Failure to conduct routine maintenance could result in equipment damage or injury to

personnel.
Proper Use of Equipment

M/D Totco equipment is designed for specific functions and applications, and should be used only
for its intended purpose.
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2: Overview
System Overview
The M/D TOTCO LM2000 is an instrument that displays the tension, payout, and speed of a cable
controlled by a winch. Information is displayed in digital and graphical form on a liquid-crystal
display (LCD). Information is presented on various screens which are user-selectable. Some
screens include bar graphs, while others include large digital readings. The most typical screen is
the Operator’s Screen in Figure 2.1.
High Alarm
Low-Low Alarm Low Alarm
High-High Alarm
L H
Numerical TENSION
2762LBS 0 5000 Bar Graph
L H
Value
PAYOUT
1000
FEET 0 5000
L H
SPEED
0
/MIN - 300 500
Keypad Label Bar
ACK PAYOUT CAL SCREEN MENU
Keypad
S/C + -
Figure 2.1: Typical Operator’s Screen
Values for tension, payout, and speed are shown both as numbers and horizontal bar graphs. The
bar graphs also show up to four alarm setpoints for low-low, low, high, and high-high alarms. More
information about alarms is in Chapter 4, titled "Normal Operation".
The instrument receives signals from sensors that measure tension, payout, and speed of a cable.
The tension sensor must have a 4-20mA output. Payout is measured by a phase-sensitive
(quadrature) position sensor. Speed is calculated by the instrument from the payout signal.
The sections that follow describe the instrument’s features and functions.
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LM2000 Specifications
Display
Graphic LCD (240 x 128 pixel)
Viewing area of 114mm wide x 64mm high
Adjustable backlight color (red/green) via front panel
Adjustable backlight brightness via front panel
Adjustable LCD contrast via front panel
Field scalable (full floating point) -999999 to 9999999 (max 7 characters) including “-” and “.”
Engineering units selectable from predefined list
Display resolution 1, 10, 100, 1000, 0.1, 0.01, 0.001, and 0.0001
Tri-color alarm status LED (green, amber, red)
Analog Inputs
One each 4–20 mA input; (2 for dual-axis option)
100 input impedance (0.4 2.0 V loop drop)
Common mode range: ±200 V operational; 024 V specified accuracy
Accuracy: 0.01% FS typical (1 part in 10,000) at 25° C
Temperature drift: 10ppm/C typical (50ppm/C max)
Common mode error: 0.016%/V (virtually eliminated if calibrated in place)
A/D Conversion:
Technique16 bit (02.5V = 065535 counts)
Resolution >40,000 counts for 420 mA
Input update rate16 Hz
Output update rate4 Hz
Digital Inputs
One quadrature position/speed input activated by:
-switch closure pulling to ground (< 3 V)
-external voltage applied (12–24 V)
-NAMUR type proximity sensor
Bandwidth 10 kHz
Sensor Excitation
24 V available for each analog input and each analog output (max 170 mA total for all 8 I/O
combined)
Position sensor power supply of 5–24 V at 100 mA
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Outputs
Analog Outputs
one for tension, one for payout, and one for speed
individually selectable module types for each parameter
three types of modules:
Non-isolated 4–20 mA sourced (1 k max load)
Non-isolated ±10 VDC (5 mA max)
Ground isolated 2-wire 420 mA transmitter (828 V), the voltage between the + and -
signal of this module must remain between 8 and 28 VDC at all times for proper
operation.
Aux Comm (Half-duplex)
RS232
RS485
Alar ms
Four alarm setpoints (2 high, 2 low) for each displayed parameter
Industry standard plug-in relays
various contact configurations and ratings available
solid state or dry contacts
latching or non-latching (front panel programmable)
fail-safe or de-energized operation
Environmental
Operating: -20 to +55° C (slow display below -10° C)
Storage: -30 to 80° C
Input Power
12–24 VDC (10 W typical, 20 W max)
Front Panel
The front panel (Figure 1-2) has five parts:
A power-on light in the upper left corner
The power-on light is green when the instrument is powered on and working normally. It
also lights up to indicate CPU self-test.
An alarm light just to the right of the power-on light
The alarm light is green when there are no alarm conditions, amber when there is at
least one low or high alarm condition, and red when there is at least one low-low or high-
high alarm condition. It also lights up to indicate CPU self-test.
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The alarm light can display three levels of alarm:

a. Green: No alarm conditions
b. Amber: High or low alarm condition
c. Red: High-high or low-low alarm condition
A Liquid-Crystal Display (LCD) in the center of the unit
The LCD shows screens of constantly updated information about line tension, payout,
and speed in the form of digital readouts and/or bar graphs. It also serves as the user
interface when calibrating or configuring the system.
A five-position keypad just below the LCD
Use this keypad to silence alarms, and enter predetermined payout lengths, alarm
setpoints, and calibration information.
A keypad label bar just above the five-position keypad
Just above each key on the keypad is a label bar displayed on the LCD that indicates
the purpose of each key. This label bar will change to match the needs of the user. For
example, the Operator’s Screen uses a different label bar from the Cal Check Screen.
Figure 2.2: Front Panel
The operator can read the LCD in sunlight; it is backlit for use at night. Moreover, the
brightness and color of the backlight can be adjusted. Color ranges from green to red in
small steps (see Chapter 5, titled "Configuration and Calibration").
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The display operates in temperature ranges from -20° C to +70° C (-4° F to +158°
F).Contrast can be adjusted via the front panel controls. The unit must be stored within
the temperature range from
-30° C to +80° C (-22° F to +176° F).
Back Panel
TB1-12/24VDC TB2-PWR OUT TB3-RS485 TB10-RLY1 TB11-RLY2
ON/OFF CHASSIS A B A B M2 M1 G2 G1 M2 M1 G2 G1
V+ S+ S- V- V+ S+ S- V- V+ S+ S- V- V+ S+ S- V-
TB4-ANLG1 TB5-ANLG2 TB6-ANLG3 TB7-ANLG4
ADJUST
CONTRAST
RESET
ADDR + A - CHS A+ A- B+ B- M2 M1 G2 G1 M2 M1 G2 G1
TB8-POS PWR TB9-POS SIG TB13-RLY4 TB12-RLY3
Figure 2.3: Back Panel
Figure 2.3 shows the back panel of the unit. Along the top and bottom edges of the back panel are
rows of terminal blocks. These terminal blocks are for connecting power and sensor wires to the
instrument, and for sending signals or power out to other instruments. The black chassis housing
has white letters to identify the terminal blocks. Each terminal block has a TB-XX label, where XX
is the terminal-block number. A short, printed phrase indicates the purpose of each terminal.
For example, the chassis near terminal block number one, in the far upper left corner, has the label
TB1-12/24 VDC and ON/OFF + -. The top half of the label, 12/24 VDC, means that TB1 is for
connecting 12 or 24 VDC power. The bottom half of the label, ON/OFF + -, means that the
corresponding terminals are for connecting an external on/off switch and for connecting positive
input voltage and a common.
At the right edge of the chassis is a row of four receptacles that can accommodate option relays,
labeled RLY1 to RLY4 (Figure 1-3). Various relay contact ratings and configurations are available.
Caution: When a Series 2000 instrument is used in Class I, Division 2, Group C & D
hazardous locations, only solid-state relay options 0, 6, 7, and 8 may be used.
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The purpose of the instrument’s relay options is to initiate external warning devices such as horns,
sirens and/or lights, or commence other external relays for remote calibration and individual
customer applications. Refer to Appendix B for more information.
In the middle of the panel is a row of four receptacles used for installing option modules. Option
Modules send scaled analog signals to external instrumentation, such as a strip-chart recorder or
a data logger; these option module receptacles are also used for interfacing auxiliary
communication option modules that use RS-232 or RS-485 connections.
There are two green screws for chassis grounding: one is at the top middle edge of the back
panel, and the other is at the bottom-middle edge.
In the lower-left corner of the back panel are three holes allowing access for adjusting the screen
contrast, setting the address of the unit on a network, and reset. Once the unit is installed, the
back panel will rarely need attending.
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3: Installation
Overview
The standard instrument is designed to be mounted in a customer supplied control panel. Connect
the wires for power, sensors, and options to the terminal blocks on the back panel of the unit.
This manual does not address sensor mounting. Install all sensors according to the manufacturer’s
recommendations.
Mounting Information
Standard Panel Mount
The standard instrument is sealed only to the front panel. This configuration is used only when the
external enclosure provides adequate sealing to the rear of the S-2000 display assembly.
Locate the desired area in the operator’s console instrument panel and cut a hole to the
dimensions shown in Figure 3.1
.075” 19mm
7.01”
178mm
130mm
5.12”
0.75”
19mm
Figure 3.1: Cutout
Caution: Installation of Series 2000 Instruments in a Class I, Division 2, Groups C and D

Hazardous location requires that the instrument be mounted in an enclosure which
requires a tool for entry into the enclosure.
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Mount the unit as follows:

Place the unit through the opening in the instrument panel (Figure 3.1 on page 19).
Clip one mounting bracket to the inner and outer vent holes on each of the four sides of the
unit.
Tighten the screws just enough to hold the bracket in place.
After attaching all four brackets, begin tightening the screws on opposite pairs of brackets a
little at a time until the gasket is compressed to about 40% of its original thickness.
Note: Do not over tighten the screws; the brackets, chassis, and bezel might be damaged.
Dashmount Option
An optional dashmount enclosure is available. This option provides NEMA-4 style sealing to the
rear of the S-2000 display assembly. Refer to drawing 220898 at the end of Appendix I for more
detail.
Heavy Duty Stainless Steel Bezel Option

This option, intended for extreme environments, provides a stainless steel bezel in placeof the
standard ABS plastic bezel. This allows the display to be mounted to an open panel. Provisions for
sealing the rear of the display assembly are included in this option, so the external enclosure need
not provide the sealing. An optional bracket can be added for dashmount applications.
Remote Data Acquisition

An S-2000 can also be used as a displayless remote data acquisition unit. In this case, a remote
display unit (or custom PC) must be used. Refer to drawing 220930.
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Wire Connection
All wire connections to the instrument are made using the 13 or more terminal blocks on the back
panel (Figure 3.2). These terminal blocks are marked TB1 through TB13. There can be an
additional four terminal blocks installed on the unit, each a part of an option module. Connect the
wires by stripping off 0.25" (6 mm) of insulation, inserting the wire into the proper terminal, and
tightening the screw firmly. Barrel-type crimp ferrules should be used on stranded wires. If
significant electrical noise is present, twisted shielded pairs are required.
ON/OFF CHASSIS A B A B M2 M1 G2 G1 M2 M1 G2 G1
ADJUST
CONTRAST
RESET
ADDR + A - CHS A+ A- B+ B- M2 M1 G2 G1 M2 M1 G2 G1
TB8-POS PWR TB9-POS SIG TB13-RLY4 TB12-RLY3
Figure 3.2: Back Panel
Power, input and output wiring shall be in accordance with Class I Division 2 wiring methods,
Article 501-4 (b) of the National Electric Code, NFPA 70 for installations in the United States, or as
specified in Section 18-1J2 of the Canadian Electrical Code for installations within Canada, and in
accordance with the authority having jurisdiction.
Warning: Explosion Hazard - Do not disconnect equipment unless power has

been switched off or the area is known to be non-hazardous.
TB1-12/24VDC (Power Input)

Connect either a +12 VDC or +24 VDC power source to TB1 as shown in Figure 3.3 on page 22. If
an external switch is used, it should be connected to the ON/OFF terminals as also shown in
Figure 3.3. Otherwise, it must be jumpered.
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The instrument has input protection for both reverse polarity and over-voltage.
External or Jumper TB1
ON/OFF
Switch
ON
OFF
12 VDC @ 2A max + +
or
24 VDC @ 1A max - -
Figure 3.3: Input Power
TB2-PWR OUT (Power Output)

TB2 supplies power to other instruments, so that several units in one instrument panel can be
connected in a daisy chain. Connect the wires as indicated in Figure 3.4. Each additional unit
connected can be turned on or off individually by connecting a switch to TB1 of each unit.
TB1 TB1 TB1
ON ON ON/OFF
OFF OFF ON/OFF
+ + + +
PWR
IN
- - - -
TB2 TB2 TB2

More
+ + +
as
- - -
Needed
CHASS CHASS CHASS
CHASS CHASS CHASS
Instrument 1 Instrument 2 Instrument 3

Figure 3.4: Output Power Daisy Chain
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TB3-RS485 (Network Communication)

TB3 is used as a communications link to connect several units together so they communicate
using the EIA RS-485 protocol. Connect the wires as indicated in Figure 3.5. Refer to Section 4
and to Appendix C for configuration information. The ground (PWR common) on each unit must be
within 5V of each other for the communications to work properly.
Daisy chaining the power as shown in Figure 3.4 on page 22 is recommended for long cable runs.
A two pair twisted shielded cable is convenient and highly recommened for this application.
A A A
B B B
A A A
B B B
Line Line Line
Monitor 1 Monitor 2 Monitor 3
Figure 3.5: Networking Series 2000 Instruments
TB4-ANLG1 (Analog Input #1)

Connect the tension sensor to TB4. Use either two-wire or four-wire 4-20 mA sensor transmitters
for the tension sensor. Connect two-wire transmitters as shown in Figure 2-6; connect four-wire
transmitters as shown in Figure 3.7 on page 24. At a full scale input of 20 mA, the analog input
drops less than 2.5 VDC across the internal 100-ohm resistor between S+ to S-. Refer to Chapter
5, titled "Configuration and Calibration", for more information.
+
V+ (+24V Output)
2-Wire
XMTR
S+ (+Signal In)
-
S- (-Signal In)
Jumper
V- (+24V Return)
Figure 3.6: Two Wire Analog Input
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TB4
PWR IN V+ (+24V Output)
4-Wire +SIG S+ (+Signal In)

XMTR S- (-Signal In)
-SIG
Common V- (+24V Return)
Figure 3.7: Four Wire Analog Input
TB5-ANLG2 (Not Used)

TB8-POS PWR (Payout Sensor Power)
TB8 supplies power to the payout sensor, if needed. Power is supplied from the + and - terminals
of TB8. The voltage is controlled by the "A" (adjust) pin of TB8.
Connect the correct supply voltage to the sensor according to the manufacturer’s
recommendations, using one of the three supply voltage wiring schemes shown below.
+5 VDC
To supply +5V to the sensor, the “A” terminal must be open (not connected), as shown in Figure
3.8.
TB8
+ +5 VDC Output
A N.C.
- Common
CHAS
Figure 3.8: +5 VDC Sensor Wiring
+24 VDC
To supply +24V to the sensor, connect the “A” terminal to PWR common, as shown in Figure 3.9.
TB8
+ +24 VDC Output
- Common
CHAS
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+12 VDC
To supply +12V to the sensor, install a 1000 ohm resistor, as shown in Figure 3.10.
TB8
+ +12 VDC Output
A
1K Ω
- Common
CHAS
TB9-POS SIG (Payout Sensor Signal)

TB9 connects the payout sensor signal wires to the instrument. Use one of four different sensor
wiring schemes as specified by the sensor manufacturer; refer to the following four subsections for
more information. Also refer to Chapter 5, titled "Configuration and Calibration".
TTL (0 to +5 VDC)
To connect a payout sensor that provides 0 to +5 VDC signals, connect the wires as shown in
Figure 3.11. The TTL signals must be referenced to the common terminal, labeled -, of TB8.
TB9
A+ TTL Phase A
A- N.C.
B+ TTL Phase B
B- N.C.
Figure 3.11: TTL Sensor Wiring
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Open Collector (NPN) Sinking (Switch to Ground)

To connect a payout sensor that provides open collector (NPN) transistor signals or switch
closures to GND, connect the wires as shown in Figure 3.12. The signals must be referenced to
the common terminal, labeled -, of TB8. When not active, the A+ and B+ terminal voltage floats at
approximately +4.5 V. The sensor must pull the voltage down to less than +3 VDC when active.
TB9
A+
A-
B+
B-
TB8
CHAS
Figure 3.12: Open Collector (NPN) Sensor Wiring
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Open Collector (PNP) Sourcing (Switch to +24 VDC)

To connect a payout sensor that provides open collector (PNP) transistor signals or switch
closures to +PWR, connect the wires as shown in Figure 3.13. When not active, the A- and B-
terminal voltage floats near ground and must be pulled up to more than +12 VDC when active. The
signal voltages must be referenced to the common terminal, labeled -, of TB8.
V-
V+
TB9
A+
A-
B+
B-
Figure 3.13: Open Collector (PNP) Sensor Wiring
NAMUR (Proximity)
To connect a payout sensor using NAMUR-type proximity sensing, connect the wires as shown in
Figure 3.14
TB8
A
Jumper +
- NAMUR
-
CHAS
TB9
A+ +
NAMUR
A- -
B+
B-
Figure 3.14: NAMUR (Proximity) Sensor Wiring
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TB10 Through TB13 (Relay Option Ter minal

Blocks)
TB10 through TB13 are the terminal blocks for connecting to relay options 1 through 4,
respectively. TB10 is the terminal block for RLY1, TB11 is the terminal block for RLY2, and so forth.
Wire the terminal blocks according to the type of relay shown in Figure 3.15.
Connection Rating Mfg. Part # M/D Totco Part #
N/A M2
N/A M1 1250 VA G-5AMP5 927003-008
Form-A G2 10 VA ODC5R 440-00080
G1
M2
Form-B
M1 1250 VA 5AMP5-B 927003-009
N/A G2 (no LED Indicator)
N/A G1
N/A M2
N/A M1 125 VA G-1AMP5-B 927003-010
G2
Form-B
G1
M2
Form-B M1 125 VA GX2-1AMP5-AB 927003-007
G2 125 VA GX2-1AMP5-AB-LC 927003-007
Form-A
G1 GX2-DRY5-AB 927003-006
Mechanical
Solid-State
N/A M2
N/A M1 2 AMPS G4 0AC5A 927003-011
G2 2 AMPS G4 0DC5 4400-00073
Form-A
G1
N/A M2
N/A M1 2 AMPS G4 0AC5A5 (NC) 4400-00073
G2
Form-B
G1
Figure 3.15: Alarm Interconnects and Relay Configurations
Caution: If Series 2000 Instruments are to be installed in Class I, Division 2, Group C and D
hazardous locations, use only the solid state relays listed above.
In Figure 3.15, Form A is normally open. If controlled in “Fail-safe” mode, then it will be closed
during normal operation, and open during alarm or power off.
Form B is normally closed. If controlled in "Fail-safe" mode, then it will be open during normal
operation, and closed during alarm or power off. Refer to Chapter 5, titled "Configuration and
Calibration" and Appendix B for more information.
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Ter minal Blocks for Analog Output/Aux Comm

Option Modules 1 to 4
Option modules 1, 2, and 3, if they are provided, supply analog output signals for tension, payout,
and speed, respectively. The purpose of these option modules is to supply a scaled voltage or
current signal, which represents tension, payout, or speed, to external monitoring instruments,
such as a strip chart recorder or a computerized data logger. Each optionmodule has a terminal
block.
For more information, see Chapter 5, titled "Configuration and Calibration", Analog Output
Calibration, or Appendix E.
Analog Output Option Modules

There are two types of analog output option modules:
Non-isolated
Ground isolated
Wiring for the non-isolated analog output module is shown below in Figure 3.16.
+24
+24 vdc
I I
OR
M V
V Load I Load
Com Com
± 10 Volt DC Output Sourced 4-20 ma

Output can Drive ≤ 1KΩ Load
Figure 3.16: Non-isolated Analog Option Module
Wiring for the ground-isolated analog output module is shown in Figure 3.17.
+24 Customer
(+24 V Not Isolated) Power Supply
vdc
4-20
Isolated + + ma
Internal
XMTR - 4-20
- ma Load
(Power Common
Not Isolated) Com
2-Wire (8V - 28V)

4-20 ma Current Loop Only
Figure 3.17: Ground Isolated Analog Option Module
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Aux Comm Modules

There are two types of Aux Comm Modules:
RS-232
RS-485
Wiring for the RS-232 Aux Comm module is shown in Figure 3.18
RS - 232
RTS (Optional)
Tx
Rx
Com
Figure 3.18: RS-232 Aux Comm Module
Wiring for the RS-485 Aux Comm module is shown in Figure 3.19.
RS - 485
Talk (Optional)
Data (A)
Data (B)
Com
Figure 3.19: RS-485 Aux Comm Module
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Even Input Module

RS - 485
SW1
SW1
SW2
SW2
Figure 3.20: Even Input Module
Event input modules are designed to connect external switches to Series 2000 instruments. The
signal is activated by the external switch closing. SW1 is typically used as a push-to-print button.
Pressing this button causes a single transmission (SS command) out of the Aux Comm port. This
button must be a momentary switch (normally open).
SW2 is typically used to reset a value to zero (tare function). In the LM2000 product, payout gets
reset to zero by closing this switch.
Note: Examples of several common interconnect drawings are shown in Appendix H.
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4: Normal Operation
Power Up
When the unit is powered on, it performs a short self-test and then shows the Operator’s Screen. If
the unit is working properly, the power-on light in Figure 4.1 turns green and there is a short,
audible beep. The alarm light in Figure 4.1 turns green if there are no values in alarm; it turns
amber or red if there are one or more values in an alarm condition.
Figure 4.1: Operator’s Screen
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Navigation Routes From the Operator’s

Screen
Figure 4.2 is a block diagram of the screens and menus that can be reached from the Operator’s
Screen.
Operator’s Screen
ACK Payout CAL Screen Menu
Figure 4.2: Navigation Routes
The functions of the keys on the Operator’s Screen are shown in "Operator’s Screen Keypad
Function":
Operator’s Screen Keypad Function
Key Function
ACK Acknowledge and silence alarms
Payout Zero or change the payout number
CAL Check tension calibrations
Screen Change the layout of the Operator’s Screen
Main Menu Exit Operator’s Screen and display Main Menu
How to Navigate Through Screens and

Menus
The unit displays the Operator’s Screen (Figure 4.1) most of the time. However, the operator can
choose one of several Operator’s Screens, depending on personal preference and which value is
most critical. Refer to "Screen Key" on page 41 later in this chapter for more information about
selecting Operator Screen layouts.
The unit has a five button keypad below the LCD that allows the operator to navigate through the
unit’s various screens and menus, and to enter configuration values. Just above these five buttons
are display labels that show the purpose of each key.
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Keypad Functionality
During setup and calibration, the keys have the functions shown in Table 3-2. The exception to this
rule is the Operator’s Screen (Figure 4.1 on page 33) and the MORE key on the MenuLabel Bar
(Figure 4.4).
Keypad Functionality in Menu Screens
Key Label Function
S/C Stop/Cancel, Exit, Abort, Escape
Move cursor
+- Change value/selection at cursor location
Enter/Select/Take action
Label Bars
The label bar is dynamic, meaning it changes to indicate the purpose of each key when the
operator navigates among the various screens and menus. There are five different label bars used
in the screens and menus:
Operator’s Screen Label Bar
Figure 4.3: Operator’s Screen Label Bar
Menu Label Bar

The Menu Label Bar (Figure 4.4) is displayed when the operator navigates to any menu.
EXIT NEXT MORE SELECT
Figure 4.4: Menu Label Bar
Item Label Bar

The Item Label Bar (Figure 4.5) is displayed when the operator selects a menu item.
Use ?? then press MODIFY
EXIT NEXT MODIFY
Figure 4.5: Item Label Bar
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Data Entry Label Bar

The Data-Entry Label Bar (Figure 4.6) is displayed when the operator wishes to modify a numeric
value.
Press ENTER when complete
CANCEL DIGIT> INC DEC ENTER
Figure 4.6: Data Entry Label Bar
ACK Label Bar

The ACK Label Bar (Figure 4.7) is displayed when the operator navigates to the Acknowledge
screen.
ENTER = Clear all relays
EXIT ENTER
Figure 4.7: ACK Label Bar
Keypad Labels on the Operator’s Screen

The following sections provide more information about the Operator Screen keypad functions and
how to use them.
ACK (Acknowledge Alar ms) Key

The ACK key allows the operator to silence an alarm horn and to clear all relays.
Figure 4.8: Acknowledge Screen
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Using the ACK key to Silence a Horn

Silence a horn as follows:
Press the ACK key on the Operator’s Screen. The ACK key automatically acknowledges
and silences the unit’s internal beeper and option relays that control external horns. The
Acknowledge Screen appears (Figure 4.8 on page 36).
If the operator wishes only to silence a horn, press EXIT. The operator’s screen (Figure 4.1
on page 33) reappears.
Using the Ack Key to Clear All Relays
Clear all optional relays as follows:
Press the ACK key on the Operator’s Screen.
The ACK key automatically acknowledges and silences the unit’s internal beeper and option
relays that control external horns. The Acknowledge Screen (Figure 4.8 on page 36)
appears.
Press ENTER. This clears all option relays. The Operator’s Screen (Figure 4.1 on page 33)
reappears.
Payout Key
Use the Payout Screen to zero an existing payout value or to enter a preset payout value.
Figure 4.9: Payout Screen
Zeroing an Existing Payout Value

Zero an existing payout value as follows:
Press the PAYOUT key on the Operator’s Screen.The Payout Screen (Figure 4.9) appears
with its first field, RESET PAYOUT TO ZERO highlighted in reverse video to indicate it is
active.
Press MODIFY. This resets the payout value to zero; the Operator’s Screen reappears.
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Entering a Preset Payout Value

Enter a present payout value as follows:
Press the PAYOUT key on the Operator’s Screen. The Payout Screen (Figure 4.9) appears
with its first field, SET PAYOUT TO ZERO highlighted to show it is active.
Press NEXT. The second field on the Payout Screen, SET PAYOUT TO highlights in reverse
video to indicate it is active.
Press MODIFY. The Operator’s Screen Label Bar changes to the Data-Entry Label Bar
(Figure 4.10), and the digit cursor appears.
Figure 4.10: Data Entry Label Bar on the Payout Screen
Use the DIGIT> key to move the cursor to the digit space to be modified. The digit that the
operator selects highlights in reverse video.
Use the INC (+) and DEC (-) keys to increase or decrease the highlighted digit. DEC can
also insert a negative sign (-) before a number if the cursor is placed in the space to the left
of the numbers.
Repeat steps 4 and 5 if needed.
Press ENTER when the desired payout number appears on the screen (or press CANCEL
to return to the original value). The system stores the number the operator entered and
redisplays the Screen Label Bar on the Payout Screen (Figure 4.9).
Press EXIT to return to the Operator’s Screen (Figure 4.1 on page 33). The payout value
that the operator entered appears as a digital value and is indicated on the bar graph.
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CAL Key
Use the Cal Check Screen to engage remote calibration circuits through optional relays in order to
verify tension sensor calibration. Refer to Chapter 5, titled "Configuration and Calibration" for more
information.
Figure 4.11: Cal Check Screen
Verifying Tension-Sensor Calibration

Use the Cal Check Screen to energize remote shunt calibration circuits through optional relays as
follows:
Press the CAL key on the Operator’s Screen. The Cal Check Screen (Figure 4.11) appears
with the CAL 1 status field highlighted in reverse video.
Press “t” or “s” to select ON or OFF. Select ON to energize remote shunt cal circuits and
OFF to deenergize remote shunt cal circuits. Verify that the TENSION value displays correct
reading.
If the operator wishes to change the setting for Cal 2, press NEXT to select CAL 2. The
selected data-entry field to the right of CAL 1 or CAL 2 highlights in reverse video to indicate
it is active.
Press “t” or “s” to select ON or OFF. Select ON to energize remote shunt cal circuits and to
OFF to deenergize remote shunt cal circuits. Verify TENSION value displays correct
reading.
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Entering Numbers Into the Scratch Pad

Use the TARGET 1, TARGET 2 and SERIAL NO. fields in the Cal Check Screen to store tension
calibration constants entered into the unit from Calibration Data Sheets or by CAL circuit
demonstration. These values are visual references to compare with the CAL circuit TENSION
value.
Note: The TARGET1, TARGET2 and SERIAL NUMBER fields are for user convenience
only. The instrument has no “intelligence” regarding these numbers.
Use the Cal Check Screen to verify tension-sensor calibration as follows:

with the CAL 1 character field highlighted in reverse video.
Use the NEXT key to highlight the desired character field to the right of TARGET 1 or
TARGET 2 or SERIAL NO. The character field that the operator selects highlights in reverse
video to indicate it is active.
Press MODIFY. The Cal Check Screen goes into Configuration Mode, brings up the
Configuration Label Bar (Figure 4.12), and displays the digit cursor.
Figure 4.12: Data Entry Label Bar on the Cal Check Screen
Use the DIGIT> key to move the cursor to the digit space (one of seven) to be modified. The
digit that the operator selects highlights in reverse video.
Use the INC and DEC keys to increase or decrease the highlighted digit.
Repeat steps 4 and 5 as needed.
Press ENTER to store the value or CANCEL to abort the selection. Pressing either ENTER
or CANCEL causes the Cal Check Screen to redisplay the Item Label Bar as shown in
Figure 4.11.
Use NEXT to highlight another TARGET field or press EXIT to redisplay the Operator’s
Screen.
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Screen Key
Figure 4.13: Screen Menu for a Sensor Display Unit
Figure 4.14: Screen Menu for a Remote Display Unit
Using the Screen Menu to Select a Screen

Layout
Select one of these layout options as follows:
Press the SCREEN key on the Operator’s Screen. The Screen Menu (Figure 4.13) appears
with the field to the right of LAYOUT highlighted in reverse video to indicate it is active.
Scroll through the list of screen layout options in the LAYOUT field by pressing “t” or “s”. The
names of the screen layout options appear in reverse video next to the LAYOUT label.
When the desired screen layout option appears inside the highlighted field, press MODIFY.
The selected Operator’s Screen screen layout appears on the unit’s LCD.
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Screen Menu Layout Options

The Screen Menu allows the operator to choose from the following Operator’s Screen layout
options:
3 bar graphs (default screen)
Digital, tension
Digital, payout
2 Bar, payout/speed
Big bar, tension
Big bar, payout
The six layout options available from the Screen Menu are described in the sections that follow. A
procedure for using this menu comes after the layout option descriptions.
3 Bar Graphs Operator’s Screen Layout

The Three Bar Graphs layout (Figure 4.15) is the default Operator’s Screen. It shows the values
for tension, payout, and speed using numbers and small bar graphs. Each bar graph shows the
range, four possible alarm set values, and the current value of the indicated parameter (shaded
areas of the bar graph). If an alarm set point is out of the indicated range, it will not be shown.
Figure 4.15: 3 Bar Graphs Screen
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Digital Tension Operator’s Screen Layout

The Digital Tension layout (Figure 4.16) shows the digital value of the tension in large numbers
across the top of the screen and the values of payout and speed in smaller numbers displayed to
the lower left and right of the screen. There are no bar graphs used in this screen.
Figure 4.16: Digital Tension Screen
Digital Payout Operator’s Screen Layout

The Digital Payout layout (Figure 4.17) shows the digital value of the payout in large numbers
across the top of the screen and the values of tension and speed in smaller numbers displayed to
the lower left and right of the screen. There are no bar graphs used in this screen.
Figure 4.17: Digital Payout Screen
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2 Bar Graphs, Payout/Speed Operator’s Screen Layout

The 2 Bar Graphs layout (Figure 4.18) shows the values for payout digitally; it also shows both
payout and speed values with bar graphs. Each bar graph shows the range, four possible alarm
set values, and the current value of the indicated parameter (shaded areas of the bar graph). If an
alarm setpoint is out of the indicated range, it will not be shown.
Figure 4.18: 2 Bar Graphs, Payout/Speed Screen
Big Bar Graph, Tension Operator’s Screen Layout

The Big Bar Graph, Tension layout (Figure 4.19) shows the value of tension in large numbers
across the top of the screen and shows a large bar graph of tension, its range, and its four alarm
set values across the middle of the screen.
Figure 4.19: Big Bar Graph, Tension Screen
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Big Bar Graph, Payout Operator’s Screen Layout

The Big Bar Graph, Payout layout (Figure 4.20) shows the value of payout in large numbers
across the top of the screen and shows a large bar graph of payout, its range, and its four alarm
set values across the middle of the screen.
Figure 4.20: Big Bar Graph, Payout Screen
Menu Key
Press the MENU key to bring up the Main Menu in Figure 4.21. This menu is the gateway to all
configuration and calibration. For a description of the Main Menu, see Chapter 5, titled
"Configuration and Calibration".
Figure 4.21: Main Menu
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5: Configuration and Calibration
This chapter shows how to navigate through and use the Configuration and Calibration menus and
screens for changing system values and presets. The operator begins from the Operator’s Screen.
For a complete description of the Operator’s Screen, refer to Chapter 4, titled "Normal Operation".
Figure 5.1 on page 48 is a menu tree that shows the navigation routes from the Operator’s Screen.
The Configuration and Calibration menus and screens are available from the Main Menu.
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Operator’s Screen
Document number

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Main
Menu
Alarm Display Graph System
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Setpoints Adjust Scales Calibration Setup
Calibration 2 Point Data Analog Out Operator Units-of- Relay Network Aux Comm
Figure 5.1: Navigation Routes from the Operator’s Screen

Check Calibration Calibration Calibration Privileges Measure Setup Setup Setup
Operator Units-of-
Privileges Measure
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Menus and Screens

The Main Menu is shown in Figure 5.2. The following is a list of Main Menu labels and their
functions:
EXIT: Exits the main menu and returns to the Operator’s Screen.
NEXT: Moves the highlight to the next item in the list of menu choices.
MORE: Displays a continuation of menu items.
SELECT: Selects the highlighted menu item and displays a submenu or screen.
Figure 5.2: Main Menu
To select an item in the Main Menu, use the NEXT key to highlight the desired item; then press the
SELECT key.
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Alarm Setpoints Screen

Use the Alarm Setpoints Screen to enter setpoint values for tension, payout, or speed.
Figure 5.3: Alarm Setpoints Screen
Entering Alar m Setpoints

Enter an alarm setpoint as follows:
Choose Alarm Setpoints on the Main Menu to display the Alarm Setpoints Screen (Figure
5.3).
Use the + or - keys to select tension, payout or speed within the highlighted character field.
The TENSION, PAYOUT, or SPEED field appears near the top of the Alarm Setpoints
Screen.
Use the NEXT key to highlight the alarm value to be modified next to HIGH-HIGH, HIGH,
LOW, or LOW-LOW. The character field to the right of the alarm parameter that the operator
selects highlights in reverse video to indicate it is active.
Press the MODIFY key to change the selected value. The Data-Entry Label Bar appears
(Figure 5.4), and the digit cursor is displayed.
Figure 5.4: Data Entry Label Bar on the Alarm Setpoints Screen
Use the DIGIT> key to move the digit cursor and highlight the digit to be modified.
Use the INC or DEC keys to increment or decrement the selected digit.
Press the ENTER key to accept the desired value or Cancel to return the original value. The
number field containing the modified digit displays the new value in reverse video. The Data-
Entry Label Bar changes back to the Item Label Bar (Figure 5.3).
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Repeat Step 1 through Step 7 above to change other alarm setpoints, if necessary.
Press the EXIT key. The Main Menu appears (Figure 5.2).
Display Adjust Screen

Use the Display Adjust Screen (Figure 5.5) to adjust the backlight brightness, color, and contrast.
The operator can set each of these numbers to any whole number between 0 and 99, where
numbers between 0 and 99 make a proportional change. For example, the number 50 sets the
backlight brightness half-way between darkest and brightest.
Display Contrast Adjust: Use the up-arrow key to darken screen contrast or the down arrow
key to lighten screen contrast.
Backlight Brightness: 0 is darkest; 99 is brightest.
Slow Update: Changes the screen update of the digital displays from 4 per second to 1 per 4
seconds. Bar graphs update at the same speed regardless. This feature is useful in extreme
cold weather applications where a slower update is necessary to compensate for slower
screen responses.
Figure 5.5: Display Adjust Screen
Adjusting Display Contrast

Choose Display Adjust on the Main Menu to bring up the Display Adjust Screen (Figure
5.5).
Use the NEXT key to select Display Contrast Adjust. Display Contrast Adjust highlights
in reverse video to indicate it is active.
Use the INC or DEC keys to adjust the screen contrast.
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Adjusting the Backlight Brightness

5.5). The Display Adjust Screen appears; the number field to the right of the Backlight
Brightness item is highlighted in reverse video to indicate it is active.
Use the NEXT key to select Backlight Brightness. The number field to the right of the
Backlight Brightness item is highlighted in reverse video to indicate it is active.
Press MODIFY to change the Backlight Brightness value. The Display Adjust Screen goes
into configuration mode, the Data-Entry Label Bar appears (Figure 5.6), and the digit cursor
is displayed.
Figure 5.6: Data-Entry Label Bar on the Display Adjust Screen
Press the ENTER key to accept the desired value. The number field containing the modified
digit displays the new value in reverse video. The Backlight Brightness now conforms to the
new setting. The Item Label Bar is redisplayed (Figure 5.5).
Adjusting the Backlight Color
5.5). The Display Adjust Screen appears.
Use the NEXT key to select Backlight Color. The number field to the right of the Backlight
Color item is highlighted in reverse video to indicate it is active.
Press MODIFY to change the Backlight color value. The Display Adjust Screen goes into
configuration mode, the Data-Entry Label Bar appears (Figure 5.7), and the digit cursor is
displayed.
Figure 5.7: Data-Entry Label Bar on the Display Adjust Screen
Press the ENTER key to accept the desired value. The number field containing the modified
digit displays the new value in reverse video. The LCD color conforms to the new screen
setting. The Item Label Bar is redisplayed (Figure 5.5).
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Adjusting the Slow Update

5.5). The Display Adjust Screen appears.
Use the NEXT key to select Slow Update. The field to the right of the Slow Update item is
highlighted in reverse video to indicate it is active.
Use the INC or DEC keys to change the value from N to Y, or vice versa.
Graph Scales Screen

Use this screen to configure the bar-graph display on the Operator’s Screen for tension, payout, or
speed. The left scale value is the left side limit in the bar-graph range, and the right scale value is
the right side limit in the bar-graph range.
Adjusting Graph Scales affects bar-graph displays only. It does not affect alarm operation or digital
readouts.
Note: Exchange the Left Scale and Right Scale values to display graph scale changes in
the opposite direction.
Figure 5.8: Graph Scales Screen
Entering Graph Scale Values

The procedure for entering Graph Scale Values is as follows:
Choose Graph Scales on the Main Menu to bring up the Graph Scales Screen (Figure 5.8).
Use the + or - keys to select TENSION, PAYOUT or SPEED. The tension, payout, or speed
label appears near the top of the Graph Scales Screen.
Use the NEXT key to highlight the LEFT SCALE or RIGHT SCALE value.
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Press the MODIFY key. The Graph Scales Screen goes into configuration mode, the Data-
entry Label Bar appears (Figure 5.9), and the digit cursor is displayed.
Figure 5.9: Data-Entry Label Bar on the Graph Scales Screen
Use the DIGIT> key to move the digit cursor and highlight the digit space to be modified.
Press the ENTER key to accept the desired value or CANCEL to return the original value.
The number field containing the modified digit displays the new value in reverse video. The
Data-entry Label Bar changes back to the Screen Label Bar (Figure 4-8).
Repeat the above procedure to change other Graph Scales, if necessary.
Calibration Submenu
Use the Calibration submenu to check sensor calibration, calibrate sensors, and to calibrate
analogoutput modules. Highlight one of the following options using the NEXT button:
Cal check
Two-point calibration
Data calibration
Analog-output calibration
Each of the above options is explained in the subsections that follow.
Choose Calibration on the Main Menu to bring up the Calibration Submenu (Figure 5.10).
Figure 5.10: Calibration Submenu
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Cal Check Screen

Use the Cal Check Screen to engage remote calibration circuits through optional relays in order to
verify tension-sensor calibration.
Figure 5.11: Cal Check Screen
Verifying Tension-Sensor Calibration

Use the Cal Check Screen to energize remote shunt calibration circuits through optional relays as
follows:
with the CAL 1 status field highlighted in reverse video.
Press + or - to select ON or OFF. Select ON to energize remote shunt cal circuits and to OFF
to deenergize remote shunt cal circuits. VERIFY TENSION value displays correct reading.
If the operator wishes to change the setting for Cal 2, press NEXT to select CAL 2. The
selected data-entry field to the right of CAL 1 or CAL 2 highlights in reverse video to indicate
it is active. Press + or - to select ON or OFF. Select ON to energize remote shunt cal circuits
and to OFF to deenergize remote shunt cal circuits. Verify TENSION value displays correct
reading.
Entering Numbers Into the Scratch Pad
Use the TARGET 1, TARGET 2 and SERIAL NO. fields in the Cal Check Screen to store tension
calibration constants entered into the unit from Calibration Data Sheets or by CAL circuit
demonstration. These values are visual references to compare with the CAL circuit TENSION
value.
Note: The TARGET1, TARGET2 and SERIAL NUMBER fields are for user convenience
only. The instrument has no “intelligence” regarding these numbers.
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Use the Cal Check Screen to verify tension-sensor calibration as follows:

with the CAL 1 character field highlighted in reverse video.
Use the NEXT key to highlight the desired character field to the right of TARGET 1 or
TARGET 2. or SERIAL NO. The character field that the operator selects highlights in
reverse video to indicate it is active.
Press MODIFY. The Cal Check Screen goes into Configuration Mode, brings up the
Configuration Label Bar (Figure 5.12), and displays the digit cursor.
Figure 5.12: Data-Entry Label Bar on the Cal Check Screen
Use the DIGIT> key to move the cursor to the digit space (one of seven) to be modified. The
digit that the operator selects highlights in reverse video.
Use the INC and DEC keys to increase or decrease the highlighted digit.
Repeat Steps 4 and 5 as needed.
Press ENTER to store the value or CANCEL to abort the selection. Pressing either ENTER
or CANCEL causes the Cal Check Screen to redisplay the Item Label Bar as in Figure 5.11
Use NEXT to highlight another TARGET field or press EXIT to redisplay the
Operator’s Screen.
Two Point Calibration Screen

Perform two-point calibrations by entering tension values appropriate for each tension sensor
used. Low Cal Point represents the lowest value of load on the line (min load). High Cal Point
represents the highest tension value (max load). These two points need not be zero or full scale,
as any two points will work. But, for good accuracy, it is recommended that the two points be
separated by at least 50% of full scale. For more information, see Appendix C. There are three
methods of entering two-point calibration:
Physical load calibration for tension ("Physical Load Calibration for Tension" on page 57)
Shunt calibration (remote calibration) ("Shunt Calibration (Remote Calibration)" on page 58)
Voltage substitution calibration ("Voltage Substitution Calibration" on page 59)
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Select the method to be used, and go to the appropriate section.
Figure 5.13: Two-Point Calibration Screen
Physical Load Calibration for Tension

Use the Two-Point Calibration Screen to enter physical load as follows:
Navigate to the Two-Point Calibration screen: Main Menu > Calibration > Two-Point
Calibration. The Two-Point Calibration Screen (Figure 5.13) appears.
Use the + or - keys to select TENSION.
Use NEXT to highlight the Signal From item.
Use the + or - keys to select SENSOR next to the Signal From item.
Use the NEXT key to highlight the Low Cal Point character field.
Apply a known minimum load to the tension sensor.
Press MODIFY. The Data-Entry Label Bar (Figure 5.14) appears, and the digit cursor is
displayed.
Figure 5.14: Data-entry Label Bar on the Two-Point Calibration Screen
Use the DIGIT> key to move the digit cursor to the digit space (one of seven) to be modified.
Use the INC and DEC keys to increment or decrement the highlighted digit.
Press ENTER to store the value or CANCEL to abort the selection. At this point, load on
sensor is read (captured) and assigned to display the value entered.
The Item Label Bar reappears.
Use the NEXT key to highlight the High Cal Point character field
Apply a known maximum load to the tension sensor.
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Press MODIFY.
The Data-Entry Label Bar (Figure 5.14) appears, and the digit cursor is displayed.
Press ENTER to store the value or CANCEL to abort the selection. At this point, load on
sensor is read (captured) and assigned to display the value entered.
Press EXIT to redisplay the Operator’s Screen.
Note: It is very important to record the numbers shown for the offset and slope or each
sensor, after they are calibrated. Keep the recorded numbers in a secure place. They can
be used to restore calibration if the unit’s data gets corrupted.
Shunt Calibration (Remote Calibration)
Use the Two-Point Calibration Screen to do Shunt Calibration as follows:
Choose SENSOR next to the Signal From item.
Apply a zero load to the tension sensor.
Press MODIFY. The Two-Point Calibration Screen will show the Data-Entry Label Bar
Key in the minimum value (usually zero) for the Low Cal Point on the screen; press ENTER.
Use the NEXT key to highlight the Signal From character field.
Use the + or - keys to select CAL 1. This engages a Shunt Calibration circuit across the
tension sensor.
Use the NEXT key to highlight the High Cal Point character field.
Press MODIFY.
The Two-Point Calibration Screen will show the Data-Entry Label Bar (Figure 5.15), and the
digit cursor is displayed.
Press ENTER to store the value or CANCEL to return the original value. At this point, load
on sensor is read (captured) and assigned to display the value entered.
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After the calibration is completed, be sure to enter Sensor in the Signal From character
field.
Voltage Substitution Calibration
Use the Two-Point Calibration Screen to do voltage substitution as follows:
Use the NEXT key to highlight Signal From.
Use the + or - keys to highlight CAL 1.
Press MODIFY. The Data-entry Label Bar appears (Figure 5.16), and the cursor changes to
the digit cursor.
To key in the appropriate tension value of the low tension standard for the Low Cal Point on
the screen, use the DIGIT> key to move the digit cursor to the digit space (one of seven) to
be modified.
Press ENTER to store the value and capture the Low Cal Point; press CANCEL to abort the
selection. The Item Label Bar reappears.
Use the NEXT key to highlight the Signal From character field.
Use the + or - keys to select CAL 2.
Use the NEXT key to highlight the High Cal Point character field.
Press MODIFY. The Two-Point Calibration Screen will show the Data-Entry Label Bar
To key in the maximum tension value of the high load standard for the High Cal Point on the
screen.
Use the DIGIT> key to move the digit cursor to the digit space (one of seven) to be modified,
use the INC and DEC keys to increment or decrement the highlighted digit.
Press ENTER to store the value and capture the High Cal Point; press CANCEL to abort the
selection. At this point, load on sensor is read (captured) and assigned to display the value
entered. The Item Label Bar reappears.
After the calibration is completed, be sure to enter Sensor in the Signal From character
field.
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Data Calibration Screen

The Data Calibration Screen provides the operator with a way to enter calibration factors directly
(manual mode). For auto mode, use the Two-Point Calibration Screen.
Use the Data Calibration Screen to enter prerecorded calibration information if, for example, data
is corrupted or lost.
Figure 5.17: Data Calibration Screen
The procedure for using the Data Calibration Screen is as follows:

Navigate to the Data Calibration Screen:cMain Menu > Calibration > Data Calibration. The
Data Calibration Screen (Figure 5.17) appears.
Use the + or - keys to select TENSION or PAYOUT.
Press Next to select Offset.
Press Modify if changes are required (else press Next to go to Step 7). The Data-Entry
Label Bar appears (Figure 5.18), and the cursor changes to the digit cursor.
Figure 5.18: Data-entry Label Bar on the Data Calibration Screen
To enter the “offset” calibration factor, use DIGIT> to move the digit cursor and highlight the
desired whole number digit position. Use the INC and DEC keys to increment or decrement
the number in the highlighted digit space.
Once the desired number is entered, press ENTER to store the value or CANCEL to return
the original value.
Press Next to select Slope.
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Press Modify if changes are required. The Data-Entry Label bar appears (Figure 4-19), and
the cursor changes to the digital cursor.
Figure 5.19: Data-entry Label Bar on the Data Calibration Screen
To enter the “slope” calibration factor, use DIGIT> to move the digit cursor and highlight the
desired whole number digit position. Use the INC and DEC keys to increment or decrement
the number in the highlighted digit space.
the original value.
Repeat Steps 2 - 10 for tension and payout until all settings are correct.
Press Exit to return to the Cal Submenu.
Payout Calibration Using Data

Calibration
Normally mounted on a sheave or drum, payout/speed sensors count up and down pulses relative
to line payout (and in some cases, speed). Each time a target passes the sensor, it registers one
count, either up or down. The actual amount of line payout represented by one pulse out from the
sensor will vary with the wire line diameter, the sheave/drum diameter, and the number of targets
installed on the sheave/drum.
If the sheave root diameter, line diameter, and number of targets are known, the payout slope can
be calculated as follows:
Calculating Payout Slope

To calculate the payout slope, you must measure the root diameter of the sheave (at the bottom of
the groove) and the diameter of the wire line being used. Use these values to calculate the
circumference of the center line of the wire line in the units of measure in which you intend to
display payout. Then, divide the circumference by the number of targets on the payout sheave to
get the amount of payout per pulse. (If an encoder is used, the one target is equivalent to one
quadrature pulse from the encoder. Therefore, in the formula below, the “number of targets” must
be replaced with “number of encoder pulses per sheave revolution.”)
Enter this number as the slope in the data calibration screen. With regard to payout, the offset
value is overridden by the front panel operator keys during normal operation. Therefore, set the
offset to zero.
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Payout Calibration Using Two-Point

Calibration
Although two-point calibration is typically used for calibrating tension, this method can also be
used for calibrating payout. Using this method allows the unit to calculate the slope automatically
however, the accuracy of the calibration will be dependent on the acccuracy of the measurement
of the paid out line.
Use the Two-Point Calibration Screen to enter physical payout as follows:
Use the + or - keys to select PAYOUT.
Use NEXT to highlight the Signal From item.
Use the + or - keys to select SENSOR next to the Signal From item.
Press MODIFY. The Data-Entry Label Bar (Figure 5.14) appears, and the digit cursor is
displayed.
Use the INC and DEC keys to increment or decrement the highlighted digit until the actual
payout value is displayed (typically zero).
Press ENTER to store the value or CANCEL to abort the selection. At this point, the payout
counter is read (captured) and assigned to display the value entered.
Use the NEXT key to highlight the High Cal Point character field
Payout a measured amount of line.
Press MODIFY.
The Data-Entry Label Bar (Figure 5.14) appears, and the digit cursor is displayed.
Use the DIGIT> key to move the digit cursor to the digit space (one of seven) to be
modified.
Use the INC and DEC keys to increment or decrement the highlighted digit to enter the
amount of line paid out. This is the actual value, not the change ().
Press ENTER to store the value or CANCEL to abort the selection.
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Press EXIT to redisplay the Operators Screen.
Note: It is very important to record the numbers shown for the offset and slope for each
sensor after they are calibrated. Keep the recorded numbers in a secure place. They can
be used to restore calibration if the calibration data gets corrupted.
Analog-Output Calibration Screen

The primary purpose of calibrating the analog output modules is to make remote equipment, such
as a meter, read the same as the values displayed by the Series 2000 instrument.
Calibrate the analog output of the option modules for tension, payout, and speed using the
AnalogOutput Calibration Submenu (Figure 5.21).
Figure 5.21: Analog Ouput Calibration Screen
In this screen, the left column represents display values; the right column represents the signal
level at the output. The screen in Figure 5.21 shows that an output signal level of 47.9% is
transmitted when the tension display value is 0 lbs. The output signal level of 87.2% is transmitted
when the tension display value is 20,000 lbs. In general, the% output value is adjusted until the
external device matches the display value (in the left column of Figure 5.21).
The input requirements of the external device will determine what type of analog output module
you need and how to calibrate it. The analog output signal value is represented on the unit’s
display as a percentage. The relationship between this percent value and the value of the output
signal (voltage or milliampere) depends on the type of module installed. Also, the exact value of
the output will differ slightly from unit to unit. Prior to connecting the output signal to the external
device, you should set the output signal value (percent) to the nominal value. For example, if a
display of measured load from 0 to 20000 lbs must create an output signal of 0–10V, then set the
analog output calibration screen as shown above in Figure 5.21. Refer to the following tables for
nominal values for isolated and non-isolated analog output modules.
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Non-Isolated Analog Voltage Output
Voltage (V) Nominal Percentage (%)
-12.18 0
-10 8.6
-5 28.2
0 47.9
+5 67.5
+10 87.2
+13.27 100
Non-Isolated Analog Current (Sourced) Output
Current (mA) Nominal Percentage (%)
0 0
4 18.3
12 55.0
20 91.7
21.8 100
Isolated Analog Current (2-wire transmitter) Output
Current (mA) Nominal Percentage (%)
3.13 0
4 4.3
12 43.5
20 82.8
23.5 100
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The procedure for using the Analog Output Calibration Screen is as follows:
Navigate to the Analog Output Calibration Screen: Main Menu > Calibration > Analog Output
Cal. The Analog Output Calibration Screen (Figure 5.21) appears.
Use the + or - keys to select TENSION, PAYOUT or SPEED.
Use the Next key to highlight the top value in the left column of the screen. This number
represents the display value for the point being calibrated.
Press Modify. The Data-entry Label Bar appears (Figure 5.22), and the digit cursor is
displayed.
Figure 5.22: Data-entry Label Bar on the Analog Output Cal Screen
Use DIGIT> to move the digit cursor and highlight the desired whole number digit position.
Use the INC and DEC keys to increment or decrement the number in the highlighted digit
space.
Once the desired number is entered, press ENTER to store the value or Cancel to return the
original value.
Use the Next key to highlight the top value in the right column of the screen. This number
represents the value of the output signal.
Note: During this procedure, the output changes in real-time as you change the %-output
value on the display. Change the value until the external device reads the same value in
the analog output calibration screen’s left column (if the external device is a display unit).
Alternatively, change the “%output” value to achieve an accurate reading on an external
current meter or volt meter.
displayed.
space.
Once the desired number is entered and the external device exhibits the correct value, press
ENTER to store the value or Cancel to return the original value.
Use the Next key to highlight the bottom value in the left column of the screen. This number
represents the display value for the point being calibrated.
displayed.
space. Make number selection based on the external display device or a digital mulitmeter.
original value.
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Use the Next key to highlight the bottom value in the right column of the screen. This
number represents the value of the output signal.
Note: During this procedure, the output changes in real-time as you change the %-output
value on the display. Change the value until the external device reads the same value in
the analog output calibration screen’s left column (if the external device is a display unit).
Alternatively, change the “%output” value to achieve an accurate reading on an external
current meter or volt meter.
To change this output value to match the unit’s corresponding displayed value, press
Modify. The Data-entry Label Bar appears (Figure 5.22), and the digit cursor is displayed.
space. Make number selection based on the external display device or a digital mulitmeter.
original value.
Press EXIT to redisplay the Calibration Submenu.
System Setup Menu

Use the System Setup Submenu (Figure 5.23) to display screens for setting:
Operator Privileges
Units Of Measure
Relay Setup Options
Network Setup
Aux. Comm. Setup
Procedures for using each System Setup screen are in the sections that follow.
Figure 5.23: System Setup Submenu
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Operator Privileges Screen

Each unit can be programmed to allow full operator access to calibration and configuration
controls. It can also be programmed to deny operator access to any or all of these controls.
For example, a display station can be programmed so that the operator has access to changing
the payout value, acknowledging alarms, and selecting data presentation; however, the operator
can be denied access to calibration and system setup controls. Access to these controls is
referred to as Operator Privileges.
The system is shipped with all privileges enabled (set to Y). After installation, privileges may be
denied (set to N) as desired.
Note: All privileges are accessible with the use of the product PASSWORD (even those set
to N).
Use the Operator Privileges Screen as follows:

Navigate to the Operator Privileges Screen: Main Menu > System Setup > Operator
Privileges. The Operator Privileges Screen (Figure 5.24) appears.
Figure 5.24: Operator Privileges Screen
Select the desired privilege using the Next key. The corresponding privilege (Y or N)
highlights.
Use the + or - keys to change the selected privilege from Y to N as required. The highlighted
privilege, Y or N, changes to its opposite.
Repeat the above procedure for each privilege to be changed.
Once the desired privileges have been entered, press EXIT.
Note: If the operator chooses N for System Setup, he will not be able to enter the Operator
Privileges Screen without a password.
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Units of Measure Screen

Use the Units Of Measure Screen to choose the units of measure and precision for displayed
numbers of tension, payout, and speed.
Caution: Units of measure are displayed text only. The calibration is NOT adjusted
automatically to follow the units. If units are changed, recalibration is required.
The precision can be set as a positive or negative number up to seven.

Positive numbers define the decimal precision. For example, a precision of 0 means no decimal
place is shown (the displayed number looks like xxx with no decimal point); a precision of 1means
xxx.x is shown; 2 means xxx.xx is shown; 3 means xxx.xxx is shown; and so forth.
Negative numbers define how many digits are rounded off. For example, 0 means that all digits of
the measured number are displayed (like xxxxx); -1 means the last digit is rounded to the nearest
ten (like xxxx0), -2 means that the last two digits are rounded to the nearest hundred (like xxx00); -
3 means that the last three digits are rounded to the nearest thousand (like xx000); and so forth.
The procedure for using the Units of Measure Screen is as follows:
Navigate to the Units of Measure Submenu: Main Menu > System Setup > Units of Measure.
The Units of Measure Submenu (Figure 5.25) appears.
Figure 5.25: Units of Measure Submenu

Press the Next key to select Units of Measure (LBS, KGS, KIPS, TONS). The corresponding
character field highlights.
Use the + or - keys to select the appropriate units of measure to be displayed.
Press the Next key to select the PRECISION character field.
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Press Modify (if a change is needed). Otherwise, go to Step 10. The Analog Units of
Measure Submenu goes into configuration mode, the Data-entry Label Bar appears (Figure
5.26), and the cursor changes to the digit cursor.
Figure 5.26: Data-entry Label Bar on the Units of Measure Submenu
space.
original value.
Press the Next key to highlight TENSION, PAYOUT, or SPEED.
Repeat Steps 2 through 8 until Tension, Payout, and Speed are configured.
Press Exit. The System Setup Submenu reappears (Figure 5.23).
Caution: If Tension or Payout units were changed, then recalibration is required.
Relay Setup Submenu

Use the Relay Setup Submenu to choose the alarm assignments and to determine whateach relay
does. Refer to Appendix B, Alarms and Relays, for more information.
The procedure for using the Relay Setup Submenu is as follows:
Navigate to the Relay Setup Submenu: Main Menu > System Setup > Relay Setup, The
Relay Setup Submenu (Figure 5.27) appears.
Figure 5.27: Relay Setup Submenu
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Use the + or - keys to select Alarm Assignment or Relay Type. The operator’s selection
highlights with a dark field to indicate it is active.
Press Select. The submenu corresponding with the operator’s selection, Alarm
Assignments or Relay Type, appears.
Alarm Assignments Submenu
There are 12 alarm sources:
Four setpoints for tension
Four setpoints for payout
Four setpoints for speed
There are four relays (alarm destinations). The Alarm Assignments Screen is used to assign each
alarm source to control any or all relays (or no relays).
Figure 5.28: Alarm Assignments Submenu
The procedure for using the Alarm Assignments Submenu is as follows:

Navigate to the Alarm Assignments Submenu: Main Menu > System Setup > Relay Setup >
Alarm Assignments. The Alarm Assignments Submenu (Figure 5.28) appears.
Press Next to select the HIGH-HIGH row, R1 column. The corresponding Y or N field
highlights.
Use the + or - keys to turn the selected alarm assignment on or off (Y or N). The highlighted
alarm, labeled Y or N, changes to its opposite.
Repeat Steps 2 through 4 for all four rows and columns.
Press Next to highlight the parameter (tension, payout, or speed).
Repeat Steps 2 through 6 until all assignments are correct.
Press EXIT.
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Relay Type Submenu

Relays are controlled in one of six different ways, depending on the function (purpose) of the relay.
The purpose of a relay is referred to as a relay type. Relay type refers to the way the instrument
controls the relay; relay type does NOT refer to the type of physical relay installed.
The term “latched” means that once a signal exceeds an alarm setpoint, the relay will remain in the
alarm state until it is acknowledged via the front panel. It has to be acknowledged even if the signal
has returned to the normal range.
The term “unlatched” means that the relay will reflect the present signal value; it does not need to
be acknowledged.
Use the Relay Type Submenu to tell the unit how to control each relay. The relay positions (Relays
1 to 4) are in the left column of the screen and the relay types are in the right column. Refer to
Appendix B for more information on relays.
The procedure for using the Relay Type Submenu is as follows:
Choose Relay Type from the Relay Setup Submenu.
Figure 5.29: Relay Type Submenu
Use the + or - keys until the desired relay type appears highlighted. Possible relay type
selections are:
Latched Horn
Latched Relay
Unlatched Horn
Unlatched Relay
Remote Cal 1
Remote Cal 2
Horn relays are normally deenergized. General purpose relays are normally energized so
that they will fail-safe in their alarm mode if power is lost.
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Press the NEXT key to go to another relay if necessary. The corresponding Relay Type field
highlights.
Repeat Steps 2 and 3 until all settings are correct.
Press the EXIT key.
The System Setup Submenu reappears (Figure 5.23).
Network Setup Screen
Use the Network Setup Screen to designate a unit as a sensor input or remote display unit.
For units designated as Sensor Input Units, it is necessary to set the rotary switch on the back of
the unit until the first unit reads “1” on the Rotary Switch field of the NetworkSetup screen. Then
use the rotary switch to set each succeeding unit such that each unit has a unique number.
For units designated as Remote Displays, it is necessary to select the Remote Display number in
the first field of the Network Setup Screen. Then use the rotary switch to match the winch number
that will most often be displayed by this remote. In the Operator’s Screen, select the winch number
to be displayed now. For more information on network setup, refer to Appendix G.
Configuring the Instrument as a Sensor Input Unit

The procedure for configuring a unit as a Sensor Input Unit is as follows:
Navigate to the Network Setup Screen:
Main Menu > System Setup > Network Setup
The Network Setup Screen (Figure 5.30) appears.
Figure 5.30: Network Setup Screen
Use the + or - keys until the top field reads SENSOR INPUT UNIT.
The top field reads Sensor Input Unit highlighted in reverse video.
Adjust the rotary switch on the back of the unit to the appropriate setting.
The number to the right of the Rotary Switch label reflects the current rotary switch setting.
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Press the EXIT key.

Configuring the Instrument as a Remote Display Unit
The procedure for configuring a unit as a Remote Display Unit is as follows:
Navigate to the Network Setup Screen:
Main Menu > System Setup > Network Setup
The Network Setup Screen (Figure 5.30) appears.
Use the + or - keys until the top field reads REMOTE DISPLAY #, where # stands for the
appropriate display number.
The top field reads REMOTE DISPLAY #, highlighted in reverse video.
Adjust the rotary switch on the back of the unit to the setting of the most commonly viewed
winch number for this remote display.
The number to the right of the Rotary Switch label reflects the current rotary switch setting.
Press the EXIT key.
Aux. Comm. Setup Screen
Use the Aux. Comm. Setup Screen to configure serial communications to a customer computer or
other device via RS-232 or RS-485 option modules. Possible configurations via the Aux. Comm.
Setup Screen are:
Choosing the protocol
Changing the data interval
Changing the data-transmission baud rate
Enabling or disabling parity
Choosing even or odd parity
Use the Aux. Comm. Setup Screen as follows:
Navigate to the Aux. Comm. Setup Screen:
Main Menu > System Setup > Aux. Comm. Setup
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The Aux. Comm. Setup Screen (Figure 5.31) appears.
Figure 5.31: Aux. Comm. Setup Screen
Note: The default number in the Data Interval (1/4 Sec) character field is 4. (A setting of 1
means that data is transmitted every 1/4 sec; a setting of 4 means that data is transmitted
every second; 8 = every 2 sec, etc.).
Press Modify.
The Data-entry Label Bar appears (Figure 5.32), and the digit cursor is displayed.
Figure 5.32: Data-entry Label Bar on the Aux. Comm. Setup Screen
To change the data interval, use DIGIT> to move the digit cursor and highlight the desired
whole number digit position.
space.
to the original value.
Press the NEXT key to highlight the PROTOCOL character field.
Use the + or - keys to scroll through the protocol choices (1, 2, or continuous mode).
Press the NEXT key to highlight the DELIMITER character field.
Use the + or - keys to scroll through the delimiter choices (comma, space, or tab).
Press the NEXT key to highlight the BAUD character field.
9600 baud is the default.
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Use the + or - keys to scroll through the baud-rate choices (9600, 19.2K, 300, 600, 1200,
2400, 4800).
Use the NEXT key to highlight the Parity Enabled? character field.
Use the + or - keys to choose Y for Yes or N for No.
N is the default.
Use the NEXT key to move the highlight to the Odd Parity? character field.
Note: If Parity Enable = No, then this field is ignored.
Use the + or - keys to choose Y for Yes or N for No.

N is the default. (Yes = odd, No = Even.)
Press EXIT to return to the Main Menu.
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6: Troubleshooting
Overview
There are three types of diagnostics available on Series 2000 Instruments:
Power-On Self Test—test routines that the unit runs to test its internal subsystems. These
tests are performed at power up and after reset during normal operation.
Run Time Background Tests—test routines that run automatically during normal operation
that detect and record errors in the entire system. This includes creating error logs.
Troubleshooting Diagnostics—tools that allow you to view the raw sensor data. By changing
the value of the signal that is input to the unit, you can look for the expected changes in the
raw data. These diagnostics also control output devices such as relays and analog outputs.
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Operator’s Screen Diagnostic Menu.

E
90-01

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Main
Menu
press the + key
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Navigating the Menus
Alarm Display Graph System

Setpoints Adjust Scales Calibration Setup Diagnostics
press the + key
Raw Power Error Self Relays Options SPI

Counts Supplies Logs Tests Diagnostics
Figure 6.1: Navigation Route from Operator’s Screen to Diagnostics Menu

Local Local Self Perform
Network Hardware Test Self
Errors Errors Results Tests
Figure 6.1 is a menu tree that shows the navigation routes from the Operator’s Screen to the
6: Troubleshooting
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Diagnostic Menus
The following subsections describe the individual diagnostic menus and examples of their use in
troubleshooting.
Raw Counts (troubleshooting diagnostic)

The raw counts screen presents you with a list of the various inputs and the raw sensor data. By
substituting a signal generator set to mimic the input in question, you can alter the input and look
for the expected change in the raw counts displayed.
Figure 6.2: Raw Counts Display
Power Supplies (run time background)

Selecting this menu item shows you a value representing each power supply in the unit. If these
values are outside the following acceptable ranges, there may be a problem with the power supply
circuit.
Acceptable Ranges
Power Supply Acceptable Range
-15 V 115-145
+15 V 90-115
+24 V 150-180
+3.84 215-240
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Error Logs (troubleshooting diagnostic)
Figure 6.3: Error Log Menu for a Remote Display
Figure 6.4: Error Log Menu for a Sensor Display
Notice that the remote display’s screen is slightly different than the sensor display. It includes
information on sensor unit errors as well as remote unit errors.
Each unit keeps a count of errors it senses during operation. If there seems to be some kind of
problem during operation, check the error logs to narrow down where the problem might be. Select
an error log by pressing the:
key to highlight it, and then press the following key:
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Local (or Sensor) Network Errors

After selecting Local (or Sensor) Network error log, you will be presented with a screen similar to
the following:
Figure 6.5: Local Network Error Log Screen for a Sensor
Recv CRC errors—number of times the system has detected errors in CRC of records
coming in from the network.
Recv sync errors—number of times the system has detected an unexpected sync
character in a record.
Buffers full—number of times the buffer was full when it needed to receive a record from
the network.
UART Errors—number of errors generated by the UART processor interface.
Search Mode—number of times the system has been put into search mode.
Timeouts—number of times the system has not received aresponse from a device it has
sent a request to.
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Local (or Sensor) Hardware Errors

Depending on whether the unit is acting as a sensor or a remote, a screen similar to the following
will be presented:
Figure 6.6: Hardware Error Log for a Sensor Unit
ADC Data Ready Errors—number of times the ADC has failed to convert data within its
allotted time.
ADC Cal Errors—number of times the ADC failed to calibrate a channel.
-15 VDC—number of failures recorded from this power supply.
+15 VDC—number of failures recorded from this power supply.
+24 VDC—number of failures recorded from this power supply.
+3.84 VDC—number of failures recorded from this power supply.
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Self Tests
In the diagnostic menu, select self test. The display will present you with the following menu:
Figure 6.7: Self Test Menu
Highlight the desired menu item using:
then press the following key:
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Self Test Results

The first time you select this self test option after power up, it will show you the results of the self
tests it ran at power up. Each time thereafter it will show you the results of the last batch of self
tests it ran. Self test results are broken down into those for the sensor components and those for
the display components.
Figure 6.8: Self Test Reults Screen
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The following is a description of what each of the self tests report:

RAM—results of a read/write test to the random access memory for both the display and
sensor. If either reading or writing errors occur, it will record this as "FAIL".
Program—results of a checksum test on the display and sensor EPROM. Software
programs are stored here.
EEPROM—results of a checksum test on the display and sensor EEPROM. Calibration and
configuration information are stored here.
ZRAM/Bank—results of a checksum test run on the sensor ZRAM and on the display
processor EPROM. ZRAM (sensor) holds payout value and less critical configuration data.
Bank holds display software data.
-15 VDC—results of check to see if power supply is working within tolerance.
+15 VDC—results of check to see if power supply is working within tolerance.
+24 VDC—results of check to see if power supply is working within tolerance.
+3.84 VDC—results of check to see if power supply is working within tolerance.
ADC/Temperature—results of a check of the analog to digital converter and the internal
temperature of the enclosure. If the result is FAIL, check the temperature raw count
diagnostic. If the raw count of the temperature is between 24,000–42,000 it means that the
ADC failed the test. If the temperature is outside 24,000–42,000 it most likely means that the
FAIL message is for temperature problems.
Encoder—results of a diagnostic test of the circuit that monitors the payout/position sensor.
Perform Self Tests
Selecting this diagnostic resets the unit and puts it through start-up and self test, but keeps the
alarm settings and graph scaling in memory. By performing the self test, it also updates the self
test results.
Load Factory Defaults

Warning: This option resets all settings to their factory defaults. Any changes
made to the screen configuration, scaling, alarm setpoints, calibrations, etc. will
be erased and replaced with the factory settings.
This diagnostic tool is useful for rebuilding a setup from scratch.
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Relays-Alar ms Disabled
This diagnostic allows you to activate and deactivate relays to ensure they are working properly.
Figure 6.9: Relays-Alarms Disabled Screen
Once you have selected this option, use the key to select the relay you want to toggle on/off. Once
this relay is highlighted, press the key, and then the + or - keys to toggle the relay.
Warning: This test procedure disables system alarm checking. This means that
alarm conditions sensed while toggling the relays on and off will not generate an
alarm in the system.
Options (troubleshooting diagnostic)

This diagnostic allows you to test any analog output modules installed on the unit. It applies a
known value (scaled in %) to the analog output module, allowing you to look for the appropriate
response from the module.
Figure 6.10: Options Diagnostic Screen
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SPI Diagnostics (run-time background)

This diagnostic tool tracks the communication between processors inside the unit, and keeps a
running count of the errors it detects.
Figure 6.11: SPI Diagnostic Screen
Recv CRC errors—# of errors detected in records sent between processors.

Collisions—number of times two or more peripherals tried to transmit info on the SPI bus at
the same time.
Xmit NAK—number of responses to records received in error over SPI bus.
Recv sync errors—number of times an unexpected sync character was detected in a
record received over the SPI bus.
Buffers full—number of times a buffer was full when it needed to receive information over
the SPI bus.
Software Update Procedure

The following are the steps involved in changing the firmware chips (software) in Series 2000
instruments. Refer to the assembly drawing (dwg # 220870) for visual information to supplement
these instructions. Note the following conventions used in the assembly drawing: a circle with a
number in it refers to an item number in the parts list, a square with a number in it refers to a note
for assemblers.
Record all calibration and installation parameters before attempting any changes to the
software.
Remove the six black screws from the rear cover (items 8 and 9).
Remove the rear cover (item 7) and the field wiring board (item 6). Note that the field wiring
board includes all of the terminal blocks, and is connected to the main boardonly by the
plug-in connector described in note 4, meaning there is no need to remove the wires to
access the main board and software.
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Refer to view A of the 220870 drawing and locate the following EPROM’s: U10, U27, and
U30. Carefully pry the EPROM’s from their sockets.
Warning: This unit can be damaged by static electricity. If a static controlled work
station is not available, always keep one hand touching one of the six metal hex-
shaped standoffs the entire time the rear cover is removed. This will help avoid
static build-up.
Gently place each new EPROM into its correct socket. Each EPROM is labeled U10, U27,
or U30. The chip MUST be oriented properly so that pin #1 is in the correct location. Note
that one end has a dot over pin #1 and a notched or chamfered corner. If there is any
question, remember...IF THE CHIP IS INSTALLED BACKWARDS, IT WILL BE
DESTROYED. Once properly aligned, press firmly to seat the chip in place.
Replace the field wiring board, rear cover and wiring. Be sure that the connector is properly
aligned and press it into place. Replace the six black screws.
Power the unit up and allow it to go through selftest.
Initialize the software as follows:
Press the F1 key. Wait one second. (The alarm screen is displayed.)
Press the F2 key. Wait one second. (The display does not change.)
Press the F3 key. Wait one second. (The display does not change.)
Press the F4 key. Wait one second. (An initialization screen is displayed.)
Press the NEXT key. (The cursor moves to the number field.)
Press MODIFY. (The unit enters the data entry mode.)
Press DIGIT>. (The cursor moves one space to the right.)
Enter the product initialization code using the DIGIT>, INC, or DEC buttons as required.
When the correct number is displayed, then press CONFIG. (Consult the factory for the
initialization code.) Standard and Single-Axis line tension-payout-speed systems have an
initialization code of 6538.
Wait 10 seconds.
Turn the power off for 5 seconds.
Turn the power back on. The unit should now be ready for operation. Verify that all
calibration constants and configuration parameters are correct.
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Error Symbols
The following table lists the various error symbols that an S-2000 instrument can display, their
meaning, and their possible causes.
Error Symbols
Displayed Data Meaning Possible Cause
Display CPU not SPI communication failed

///////
receiving current values ADC in self-calibration
/////// Invalid data ADC in self-calibration
/////// Invalid data Sensor channel not configured
/////// Invalid data Algorithm not defined
/////// Invalid data Divide by 0 error
/////// Invalid data No DRDY from ADC
/-----/ + or - infinity No DRDY from ADC
/-----/ + or - infinity Format conversion error (bad data)
Data doesn’t fit in display

------- Value < -999999
field (>7 digits)
Remote display not

------- receiving current values Selected sensor unit not on-line
from sensor input display
Data doesn’t fit in display

/-/-/-/ Value > 9999999
field (>7 digits)
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A: Glossary
Alarm A condition reached when a measured parameter exceeds or goes below

operator defined normal operationg limits.
LCD Liquid-Crystal Display
LED Light-Emitting Diode
Label Bar A display just above the keypad which shows the function of each key. The keys
in the keypad can have different functions in different levels of the menu and
screen hierarchy.
Load Cell A type of sensor
Menu A display of options that allows the operator to change system values or to
navigate to a screen or a submenu.
N.C. Normally Closed or Not Connected
N.O. Normally Open
Navigation Moving through the hierarchy of menus, submenus, and screens by pressing
the keys below the display.
Networking Connectiong two or more instrument together with RS-485 communications
links so that the operator can view the information from a remote display.
Operator’s This is the default operating screen. The operator can choose from several
Screen different screen layouts to optimize parameter viewing.
RS-232 Recommended Standard 232. Describes the signal function and voltage levels
of a communication standard. Typically used by PCs.
RS-485 Recommended Standard 485. Describes the signal function and voltage levels
of a communication standard. Typically used in party-line (or multi-drop)
communications.
Reverse Video A convention to indicate a menu item is selected and active. In reverse video,
what is normally white on the LCD changes to black, and what is normally black
changes to white
Screen Displayed image format on the front of the instrument.
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B: Alarms and Relays
Overview
The purpose of this Appendix is to describe the alarm and relay characteristics for the M/D TOTCO
Series 2000 instrument family. Items discussed include contact types, software control of relays,
alarm operation, and functions accessible from the front panel of the instrument.
Series 2000 instruments are equipped with 4 relay sockets. Optional relays can be installed in
these sockets for alarm or calibration purposes. The sockets can accept various types of relays, as
described below. Programming of the relays is achieved using the keys below the display.
Relay Contact Types

When using Series 2000 instruments, various combinations of contact types and ratings are
available. These include "pilot" relays with 10 VA contact ratings, multi-purpose relays with 125 VA
contact ratings, and special high power relays with 1250 VA contact ratings. Solid state relays with
2 amp contact ratings are also available. The following subsections describe the different styles of
contacts.
Nor mally Open Contacts vs. Nor mally Closed

Contacts
There are three basic contact styles:
Form A contacts are normally open (N.O.); energizing the coil closes the contacts.
Form-A
de-energized energized
Form B contacts are normally closed (N.C.); energizing the coil opens the contacts.
Form-B
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Form-C contacts act like a single pole, double throw (SPDT) switch. Internal to this type of
contact is both a normally open and a normally closed contact, and a common. The Series
2000 does not have a Form-C contact; instead, a relay can be installed that has both a
Form-A and a Form-B contact (Form-1A/1B). This is more flexible because you can wire it to
behave like a Form-C, or use it as two separate contacts.
Form-C
normally closed (N.C.)
common
normally open (N.O.)
Form-1A/1B (wired as a Form C)
Form A Form A
Form B Form B
Mechanical Contacts vs. Solid State Contacts

Series 2000 instruments can use either solid state or mechanical contacts, except in hazardous
(Div 2) applications where only solid state relays are allowed.
Note: When choosing a solid state relay, you must know what kind of power the contact will
be switching. Solid state relays for AC power are NOT interchangeable with solid state
relays for DC power.
Horn vs. Relay

For Series 2000 instruments, relays are lumped into three general types:
Horn Relays
General-Purpose Relays
Cal Relays
The following subsections describe the ways in which the software controls the relays. Please
note, however, that this information pertains only to software control, not the relays themselves.
Fail-safe vs. De-energized

Fail-safe control of a relay means that the coil is held energized during normal operation; the coil is
released (de-energized) during alarm conditions. This means that if power to the instrument fails,
the relay will go to the alarm condition.
Note: Fail-safe describes the way the coil of the relay is controlled; it has nothing to do with
the contacts of the relay being normally open or normally closed.
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Hor n Relay vs. General-Purpose Relay

Each kind of relay can be programmed to specifically control an external horn or to be used as a
general-purpose alarm relay.
HORN—relays meant specifically to control external horns. These relays are de-energized during
normal operation, and energize when in an alarm condition. They are immediately de-energized
when the ACK button is pressed. The operator is then given the option to clear the general
purpose relays.
RELAY—meant for general purpose alarm use, and are controlled fail-safe.
Latched vs. Unlatched

Each relay, horn or general-purpose, can be programmed to operate latched or unlatched.
LATCHED—relays and horns that must be manually acknowledged via the front panel of Series
2000 instruments. This means that if the alarm condition goes away, the horns and relays stay in
the alarm condition until they are manually cleared.
UNLATCHED—relays or horns that are self-acknowledging. If the alarm condition goes away, then
the relays clear and the horns (if any) silence automatically.
Cal Relays
These are special purpose relays meant for controlling calibration circuits in external signal
conditioners. Up to two cal relays can be programmed via the front panel. In applications that use
shunt calibration, only one cal relay is needed. This relay is normally installed in relay socket 4 on
the back of a Series 2000 instrument. In applications using voltage substitution, both cal relays
must be used.
Note: Cal relays take up space that could otherwise be used for alarm relays. If a relay
socket is defined as a cal relay, that socket cannot be used for any other purpose until the
unit is reprogrammed.
On strain gauge input versions of Series 2000 instruments, there is one cal relay built into the
system internally, in addition to the 4 external relays on the back of the unit. This built in relay has
two normally open contacts. When these contacts are closed, they can activate two shuntcal
resistors located on the terminal blocks on the rear of the unit.
Alarm Operation
Each measured or calculated channel has four alarm setpoints (2 high & 2 low). Each setpoint is
individually programmed via the front panel. Each alarm source can be individually assigned to
one or multiple relays. It is also possible to assign multiple alarm sources to a single relay.
TRI-COLOR LED—located on the front of the display, second from the left. The different colors of
the LED represent differing levels of alarm.
Green (normal operation)= no alarm
Yellow (caution)= at least one alarm source is in low or high alarm
Red (overload)= at least one alarm source is in high-high or low-low alarm
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FLASHING DIGITS—when a particular parameter goes into alarm condition, the digits displaying
the value of the parameter on the display start flashing. They flash even if the alarm is
acknowledged, and only stop flashing when the alarm condition goes away.
AUDIBLE BEEP—sounds when at least one alarm source is in low or high alarm condition. The
beep is silenced by pressing the ACK button, or when all of the alarm conditions are gone.
Caution: The audible beep on Series 2000 instruments is not meant to be used as a
warning device in industrial environments because it is not loud enough to serve that
purpose. Its primary purpose is to provide audio feedback for key presses.
AUX COMM ALARM STATUS CHARACTERS—the alarm status of each parameter is also
transmitted on the aux comm data package. Refer to the aux comm protocol for more information.
RELAYS—react as programmed to indicate alarm conditions.
ACK & SILENCE—front panel button that ACKnowledges alarms. Pressing this button during
alarm conditions silences the audible beep and resets all relays programmed as horns. The
operator has two choices: continue with no further change or clear all general purpose relays and
continue.
Alarm and Relay Programming via the

Front Panel
Alarm assignments and relay programming are accomplished through the front panel of Series
2000 instruments.
Alar m Assignments
Each alarm source can be assigned to control any or all alarm destinations (in any combination
desired):
Alarm Sources (for each parameter) Alarm Destinations
High-High (overload) Relay 1
High (caution/approach) Relay 2
Low Relay 3
Low-Low Relay 4
A setpoint value for each of these alarm sources can be entered via the front panel.
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Relay Types
Relay functions must be selected via the front panel of Series 2000 instruments, with six relay
types to choose from. This selection determines the way the software controls the relay; it does
NOT refer to the type of physical relay installed. The choices are as follows:
UNLATCHED HORN—meant to drive external horns
LATCHED HORN—meant to drive external horns
UNLATCHED RELAY—fail-safe control of general purpose alarm relay
LATCHED RELAY—fail-safe control of general purpose alarm relay
CAL 1—meant to control external calibration circuits
CAL 2—meant to control external calibration circuits
Tips and Hints

Use assignments that come as close to matching the default assignments as possible. For
example, shuntcal relays are installed in relay socket 4, horns are defaulted to relay 1. Keep
these assignments if possible.
General purpose relays are run fail-safe. This means that the actual relay contacts installed
should have the opposite logic of what is desired in the system. For example, when a Form-
A contact is controlled by the software as fail-safe, it will be closed in normal operations, and
open in alarm conditions. Likewise, if a Form-B contact is controlled by the software as fail-
safe, it will be open during normal operations, and closed in alarm conditions.
The Gx2-1amp5-AB-LC relay (P/N 927003-007) has both Form-A and Form-B contacts (a
Form-1A/1B). This offers the most flexibility in the system.
High-High
Setpoint
High
Setpoint
Value
Load
Low
Setpoint
Low-Low
Setpoint
Time
The diagram above shows how a Series 2000 instrument reacts to changes in load value
overtime. The darkened bars represent the “on” or “activated” condition of a component.
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C: Strain Gauge Sensor Calibration
Overview
There are four recommended techniques for calibrating strain gauge sensors:
Physical Calibration—calibrates the sensor with an accurately known load
Shunt Calibration (Shuntcal)—shunts one leg of the strain gauge bridge with a precision
resistor
Voltage Substitution—substitutes the entire strain gauge bridge with a precision resistor
divider in order to produce a specific mV/V value
Bridge Substitution—same as voltage substitution, only the strain gauge bridge is used as
part of the resistor divider
Physical calibration is the most desirable technique because it takes into account all possible parts
of an installation by directly loading the sensor. However, many applications will not allow for a
physical calibration, which means that the sensor will have to be calibrated using simulated loads.
Each of the calibration techniques described in the following sections assumes the sensor reacts
in a linear fashion to increasing load. This means that the calibration techniques are all of a 2-point
variety, with the two points defining the linear response of the sensor.
As with any 2-point calibration, the farther apart the data points are, the more accurate the
calibration. As a general rule, try to take one data point from somewhere less than 25% of total
capacity, and a data point from somewhere above 75% capacity.
Physical Calibration
Calibration is done by applying an accurately known load to the system, and adjusting the display
to match the known load value. It is recommended that every installation get a physical calibration
at least once, preferably at commissioning.
Physical Calibration Procedure

Remove all load from the system so that the system is in a condition where the measured
value on the display should read zero. Although the low cal point doesn’t need to be zero,
zero is often the easiest data point to obtain.
Adjust the display to read zero.
Apply a known physical load.
Adjust the display to read the actual value of the known load.
Remove the load and verify that the display reads zero again.
Activate each calibration circuit in the system (shuntcal, voltage substitution, bridge
substitution) and record the values of each for future reference.
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Shunt Calibration (Shuntcal)

Calibration is done by shunting one leg of the strain gauge bridge, (-) excitation to (-) signal, with a
precision resistor, see Figure C.1. This creates a repeatable change in the output signal of the load
cell. The actual value depends on the value of the resistor and the resistance of the strain gauge
bridge.
+Ex
-Sig +Sig
Shuntcal Resistor
Shuntcal Switch -Ex

Figure C.1: Shunt Calibration Diagram
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Shuntcal is a relative calibration, creating a known (change) in the output. For example, assume
that the shuntcal value for a given application is 80%. If the load displayed prior to activating the
shuntcal switch is 12%, then the display should read 92% after activating the shuntcal circuit. This
change depends on the value of the resistor and the resistance of the bridge itself. Refer to the
following table:
Shuntcal Value Approximations
Bridge Full Scale ShuntCal Approx.

(ohms) Resistor Output
(ohms)
175 1.0 50K 0.87
175 2.0 25K 1.74
350 1.0 100K 0.87
350 1.5 75K 1.16
350 2.0 50K 1.74
350 3.0 34.14K 2.55
700 1.0 200K 0.87
700 1.5 150K 1.16
700 2.0 100K 1.74
700 3.0 75K 2.32
Note: The output of each individual load cell is recorded during its factory calibration.
These output values are supplied on the Calibration Certificate that accompanies each
load cell from the factory. Shuntcal resistor and data are not automatically supplied with all
sensors and must be specifically ordered with the system.
Shuntcal Procedure
Remove all load so that the system is in the condition where the measured value is zero (or
as close to zero as possible).
Adjust the display to read zero (or the known minimum load).
Activate shuntcal and adjust the display to read the value that was recorded when the
shuntcal circuit was activated during physical calibration (plus any minimum load present
from the step above). If no previous physical calibration was performed, use the shuntcal
value from the load cell calibration certificate.
Note: The value on the calibration certificate refers to the actual load applied to the load
cell, not necessarily the measured load shown on the display.
Deactivate shuntcal and verify that the display reads zero (or the known minimum load
again).
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Voltage Substitution
This method of calibration replaces the load cell’s strain gauge bridge with a precision resistor
divider. The divider consists of three resistors in series with excitation applied to the endpoints, and
the signal read off the center resistor. See Figure C.2
+Ex +Ex
+500R +500R
+Sig +Sig
R 0.1 R
-Sig -Sig
+500R +500R
-Ex -Ex
High Cal Point Divider Low Cal Point Divider
Figure C.2: Resistor Divider for Voltage Substitution Calibration (resistor values shown as
examples only)
Depending on the values of the divider’s resistors, any "mV/V" value can be created. The center
resistor has a much smaller value than the other two, and the low cal point center resistor has a
small value compared to the high cal point center resistor. If the low cal point center resistor is
actually a short between +Sig and -Sig, then a true 0.0 mV/V value is applied. Two separate
dividers give you the high and low calibration points.
Voltage substitution creates a specific mV/V value that is independent of the load on the load cell.
This makes it a popular calibration technique for those applications where the load cell is a
structural load-bearing member, when the load cell is monitoring mooring lines for large permanent
structures, or any time load cannot be removed for calibration.
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Voltage Substitution Procedure

Obtain the records of the first physical calibration of the load cell, and look up the values
recorded for the voltage substitution check done at that time. If this information is
unavailable, obtain the calibration certificate that came from the factory with the load cell,
and see if it has specially recorded cal factors for voltage substitution.
Activate the Low Cal Point and adjust the display to match the value specified on the
documents listed in step 1.
Deactivate the Low Cal Point.
Activate the High Cal Point and adjust the display to match the value specified on the
documents listed in step 1.
Deactivate the High Cal Point.
Activate the Low Cal Point again and verify that the displayed value is the same as it was at
the end of step 2.
Caution: The values on the calibration certificate pertain to load on the load cell, and do not
take into account any tare load (zero offset).
Note: Zero offset cal factors are not routinely recorded on the calibration certificate, except
when specifically requested on special "turn-key" systems.
In some cases, the values substituted are zero and full scale. This can create problems if the
instrumentation does not have sufficient headroom below zero and above full scale. This
headroom is required as a result of tare loads and load cell output tolerances. In cases where this
is a concern, mV/V values can be chosen that will prevent this from being a problem. For example,
the substituted values can be approximately 15% and 90% of full scale. This creates sufficient
headroom even in cases where the instrumentation cannot display values below zero or above full
scale.
As a troubleshooting tool, this method verifies all circuits from the signal conditioner input through
the display. It does not verify the load cell or the load cell wiring.
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Bridge Substitution
This calibration method is similar to voltage substitution, except that the center resistor in the
resistor divider is the strain gauge bridge itself. See Figure C.3
+Ex +Ex
175KΩ 1750KΩ
+Sig +Sig
Strain Strain
350Ω Gauge 350Ω Gauge
Bridge Bridge
-Sig -Sig
175KΩ 1750KΩ
-Ex -Ex
High Cal Point Divider Low Cal Point Divider
Figure C.3: Resistor Divider for Bridge Substitution Calibration
The advantages of this method are that it checks the two signal wires to the bridge and checks that
the input resistance of the bridge is reasonably close to what it should be. The disadvantages of
this method are that it is more difficult and costly to implement, calibration constants become more
difficult to deal with, and it can actually make troubleshooting the system more complicated.
Application Notes
When a system is defined, the decision of what kind of electrical calibration to use should be
settled during system definition prior to sale. As a rule of thumb:
If the load can be removed routinely, such as a simple crane application, then choose shunt
calibration.
If the load cannot be removed easily, then choose voltage substitution.
At this time, one should also start planning for a physical calibration at the commissioning of the
system. This physical calibration must be performed at least once so that accurate cal constants
can be acquired. These values become the calibration constants for future maintenance and
routine calibrations.
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Routine Calibration
Provided you have calibration constants from a good physical calibration, frequent checks of
system calibration can be accomplished by closing a switch and making sure the displayed value
matches the recorded value.
This means that in most applications, daily calibration checks can be performed by the operator.
Maintenance personnel are not needed except to resolve situations where the displayed value
does NOT match the recorded value.
Product Features
2077 Motherboard
Shuntcal 1 - standard
Shuntcal 2 - optional
Voltage Substitution - optional, full scale configure per job
Voltage Substitution - optional, shorted for zero
SC103
Voltage Substitution (0.2 mV/V) for zero
Voltage Substitution (0.4 mV/V) for 0.5 mV/V sensor (Dipswitch selectable)
Shuntcal or other values of Voltage Substitution available on special order
Series 2000 Instruments
Optional calibration relays for driving remote calibration circuits—shuntcal, voltage
substitution, bridge substitution, or others
Strain gauge input version has on-board shuntcal relays standard—shuntcal resistor(s)
mounted on the terminal blocks on the rear of the unit
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D: Load Cell Troubleshooting
Overview
This chapter provides technical information to assist field personnel in troubleshooting load cells.
The first part of the chapter discusses background information about load cells. The last part of the
chapter deals with the techniques used to troubleshoot load cells.
Caution: The following information is not meant to be a substitute for proper training. This
information is provided as a guideline for technicians.
Excitation Voltage Requirements

Systems supplied by M/D TOTCO typically use a constant DC voltage supply. Typically, excitation
voltages range from 5VDC to 15VDC. If the supplied voltage is higher than the strain gauge is
designed to handle, it can damage the strain gauge. If the voltage is too low, the signal it yields will
be so low that it will get lost in electrical noise. The following are examples of M/D TOTCO parts
and the excitation voltages they supply:
Part Excitation Voltage
2060 signal conditioner 6.9 VDC
2078 signal conditioner 6.9 VDC
CLM 200 signal conditioners 5.0 VDC
1.25 VDC, 2.5 VDC, 5.0 VDC,

S-2000 instruments have user selectable excitation voltages
and 10 VDC
The exact absolute value of the excitation voltage is typically not the primary concern. The primary
concern is the stability of the voltage level over time and changes in temperature. Exceptions to
this are instruments which "ratiometrically" track change in excitation voltage over time or change
in temperature. These instruments internally compensate for the drift in excitation voltage. M/D
TOTCO (Metrox) instruments typically are configured for stable, absolute voltage supplies.
The excitation voltage must also be as free of electrical noise as possible. Excitation voltage must
be measured at the load cell if possible. There will be a voltage drop in the interconnect cables
between the signal conditioner and the load cell itself. In applications using long cable runs (>50')
or requiring higher accuracy, remote sense techniques compensate for this voltage drop, which
will be discussed later in this appendix.
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Load Cell Signal

A strain gauge bridge supplies a very small electrical signal proportional to the force being
measured. The signal itself is a differential signal. This means that the value of the signal is the
difference between the voltage read off of opposite sides of the bridge, as shown in Figure D.1
+Exitation
Voltage (+Ex)
+Signal Strain -Signal

Gauges
-Exitation
Voltage (-Ex)
Figure D.1: Signal Detection Points
The value of +signal and -signal have meaning only in reference to each other. The signal is not
measured with respect to ground. The signal must be measured with equipment having high
impedance inputs, otherwise current will be pulled through the signal wires causing errors. Most
modern digital volt meters (DVM’s) have sufficiently high impedance inputs so as not to degrade
the signal.
The value of the signal output from a strain gauge bridge is very low, typically 0–10 mV or 0–20
mV. Therefore, any volt meter used to measure these signals must have the capability to measure
these low signal levels. For troubleshooting in the field, the minimum voltmeter requirement is
typically a 4 ½ digit DVM.
The value of the signal is proportional to both the excitation voltage and the applied load.
Therefore, the unit of measure for these signals is expressed in millivolts of signal per volt of
excitation (mV/V). That is, for each volt of excitation supplied, you get some millivolt of signal. For
example, if a load cell has an output of 2.0mV/V, and it has an excitation voltage of 10VDC applied
to it, then the signal level should be 20mV (2mV for every volt of excitation; 2 x 10=20).
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Bridge Resistance
Generally, Metrox sensors from M/D TOTCO are configured in a Wheatstone bridge as shown in
Figure D.1. Total bridge input resistance is measured from (+)Ex to (-)Ex. Bridge output resistance
is measured from (+) Signal to (-) Signal.
Note: When measuring bridge resistance, the bridge must be disconnected from the
instrumentation and there must be absolutely NO electrical connection to the bridge except
the ohmmeter.
Typical bridge output resistance values are 350 or 700 ohms . Input resistance should be the same
as the output resistance, however, there are systems where the input resistance is greater due to
internal compensation, which is usually less than 100 ohms . Refer to the specification control
drawing for the nominal bridge resistance of a particular load cell.
Insulation Resistance
The body of each load cell is electrically isolated from the bridge. To measure the insulation
resistance of the load cell, the bridge must be disconnected from its instrumentation, and there
must be NO power applied. Resistance can be measured from any or all bridge leads to the body
of the load cell. This resistance must be greater than 100M ohms. Typically, values are greater
than 5000M ohms.
Warning: DO NOT use a high-voltage Hypot tester! Test equipment must apply no
more than 50 VDC. If internal varisters are used for lightning protection, the test
equipment must apply no more than 20 VDC.
The average DVM applies less than 9 VDC, so it shouldn’t cause any damage. However, many of
these DVM’s are often unable to measure as high as 100M ohms.
Interconnect Techniques
All full bridge load cells require a minimum of four interconnect wires:
+E x
+Sig Signal Conditioner,
Display,
-Ex Recorder,
+Sig Etc.
Figure D.2: 4-Wire Configuration Diagram
Interconnect cables need to be twisted, shielded pairs. The two excitation lines are one twisted
pair, and the signal lines are a second twisted pair. Shields are normally connected to ground only
at the instrumentation end and not at the sensor end.
If even a small amount of current flows through the excitation wires, it creates a voltage drop. This
drop means that the excitation voltage at the load cell is less than the excitation voltage at the
instrument, which causes errors in the measurements being taken. To overcome this, you can run
an additional twisted pair of wires from the load cell to the instrument, so the instrument can
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remotely sense the voltage at the load cell. The instrument can then compensate for the voltage
drop in the excitation wires. Remote sense is recommended for all applications with long cable
runs, or for applications that require a high degree of accuracy. Cable runs of less than 50 feet that
don’t require high accuracy typically do not need remote sense.
+Remote Sense Signal Conditioner,

+E x Display,
Recorder,
+Sig
Etc.
-Remote Sense
-Ex
-Sig
Shunt Cal
Figure D.3: 6- or 7- Wire Configuration Diagram
When remote sense and shunt calibration are included together in the same application, a seventh
wire is usually added to provide a current carrying path that is separate from the -Signal wire. This
information is used by the instrument to overcome error induced by the current flow. Refer to
Appendix C for more information on shuntcal.
Troubleshooting Techniques
The following are functional tests for strain gauge load cells. The tests described below should be
performed before requesting field support. Use the page at the end of this appendix to record the
results so they will be easily accessible when working with field support.
Insulation Resistance
Disconnect the load cell from the interconnect cable if attached by a connector or terminal
block.
Measure the resistance from any or all leads to the body of the load cell.
Warning: DO NOT use a Hypot tester! Test equipment must apply no more than 50
VDC. If internal varisters are used for lightening protection, the test equipment
must apply no more than 20 VDC.
If the resistance is less than 100M ohms, the load cell is faulty.
Cable Insulation Resistance
(Does Not Apply To Integral Cables)
Disconnect the interconnect cable from both the load cell and the instrument.
Verify that the insulation between each wire is good by measuring the resistance between
each wire, making sure it meets spec.
Verify that the insulation between each wire and the shield is to spec.
Bridge Resistance
Disconnect the load cell from the interconnect cable.
Measure the bridge resistance and verify it is to spec.
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Reconnect the interconnect cable to the load cell, and disconnect the cable from the
instrument.
Measure the bridge resistance through the cable. It should be within a few ohms of the
bridge resistance measured at the load cell.
Note: Measuring the bridge resistance through the interconnect cable only verifies that the
cable makes connection. There can still be wiring errors, such as swapped polarities on the
signal or excitation wires. Therefore, in all new installations, a pin-to-pin verification must
be performed.
Excitation Voltage
Disconnect the load cell from the interconnect cable.
Connect the instrument to the interconnect cable, and power the instrument.
Verify that the excitation voltage at the load cell end of the cable is to spec.
Signal Voltage
Connect load cell to instrument.
Verify that the voltage between (-) excitation and (-) signal is ½ of the excitation voltage.
Verify that the voltage between (-) excitation and (+) signal is ½ of the excitation voltage.
Using a digital volt meter that can measure small voltages, verify that the voltage between
(+) signal and (-) signal is less than 2mV when there is no load applied to the load cell.
Apply some load to the load cell and verify that the signal voltage increases with the right
polarity.
Activate the shunt calibration and/or the voltage substitution circuits and verify their
operation.
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Troubleshooting Field Notes

from Section D-7-1
Insulation resistance ohms
from Section D-7-2

Lowest cable insulation resistance ohms
from Section D-7-3

Bridge resistance at load cell:
input ohms
output ohms
Bridge resistance through cable:
input ohms
output ohms
from Section D-7-4

Excitation Voltage (Vex) V
from Section D-7-5

+Signalex V
-Signalex V
Signal mV
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E: Option Modules
Overview
Series 2000 instruments can accept up to four plug-in option modules, which are used for
interfacing with external equipment. Examples include serial communications, analog output, etc.
Located on the back of Series 2000 instruments, under the break-away tabs labeled OPT1, OPT 2,
OPT 3, and OPT 4, are four 28-pin sockets for option modules.
ON/OFF + - + - CHASSIS A B A B M2 M1 G2 G1 M2 M1 G2 G1
RLY1
RLY1
RLY2
RLY2
RLY3
RLY3
OPT1 OPT2 OPT3 OPT4 RLY4
RLY4
+ -
ADJUST
CONTRAST
RESET + A - CHS A+ A- B+ B- M2 M1 G2 G1 M2 M1 G2 G1
ADDR TB8-POS PWR TB9-POS SIG TB13-RLY4 TB12-RLY3
Figure E.1: Series 2000 Back Cover
Electrically, all sockets are identical with the exception of pin 1, which is an “address” or “select”
line. As a result, some module types work the same in all four sockets, and some have different
functions depending on which position they are installed. The model code reflects which module is
installed in which socket at the factory. Option modules may also be field installed.
Warning: EXPLOSION HAZARD - When in hazardous locations, turn off power

before replacing or wiring modules.
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Analog Output Module

There are two different types of analog output modules:
NON-ISOLATED—provide a sourced 4–20mA signal as well as a +/- 10VDC output signal. Signals
are referenced to the + 24VDC power supplied by the Series 2000 instrument.
ISOLATED—provide a ground isolated 4–20mA signal. This signal appears to external equipment
like a 2-wire transmitter. A 24VDC power supply is available via the terminal block for
convenience, but it is NOT isolated.
Although any analog output module will work in any socket, each socket is assigned a particular
parameter. For example, on an LM2000, socket #1 is assigned to tension, #2 is payout, and #3 is
speed (#4 not applicable). Likewise, on a CI2000, socket #1 is main fall gross load, #2 is whip fall
gross load, #3 is boom angle, and #4 is aux fall if applicable. Any or all applicable analog output
modules can be installed at one time. You can freely mix isolated and non-isolated analog
modules.
Aux Comm Module

The purpose of the aux comm output is to provide the real-time value of the measured parameters
to external customer equipment, such as computers, data loggers, etc. Aux comm also allows
some operator commands to be transmitted from the external device into the instrument. These
commands include acknowledging alarms, activating calibration relays for cal verification,
performing or reporting self-tests, and resetting certain values to zero. Aux comm cannot be used
for calibration or configuration.
There are two different analog output modules used for aux comm:
RS232
RS485
Instrument software responds the same regardless of which module is installed; the system acts
like a half duplex party line (even with RS232). For a detailed description of the aux comm
protocol, refer to Appendix F.
Aux comm modules may be installed in any of the option module sockets, but typically they are
installed in the OPT 4 socket.
Note: Only one aux comm module can be installed per instrument at any one time.
Even Input Module

The purpose of the event input module is to allow you to connect external switches to Series 2000
instruments. This module can be installed in any of the option module sockets. Event input
modules can accommodate two switches. Typically, this option is used for external reset (value to
zero) and push to print (transmits present value out through aux comm).
Note: Only one event input module can be installed per instrument at any one time.
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Installation
Locate the four rectangular tabs on the back of the instrument labeled OPT 1, OPT 2,OPT 3,
and OPT 4.
RLY1
RLY1
RLY2
RLY2
RLY3
RLY3
RLY4
+ -
ADJUST
CONTRAST
RESET + A - CHS A+ A- B+ B- M2 M1 G2 G1 M2 M1 G2 h G1
Figure E.2: Series 2000 Back Cover (Option Module Socket Covers Highlighted)
Remove the rear cover by loosening the six, black retaining screws securing the cover to the
unit.
Break out the appropriate tabs to expose the required option module sockets.
Verify that all of the pins on the bottom of the option module are straight. If necessary,
carefully bend them back straight. All pins must be straight for the module to fit in the
instrument.
Using the four long guide pins, carefully position the module over the socket.
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Place your fingers on the terminal block and the edges of the housing and press firmly until
the module is fully seated in the socket. DO NOT apply excessive force to the center of the
housing. Refer to Figure E.3.
Press here
+ + - R
2 4-20mA E
4 Isolate T
V
Press here
Figure E.3: How to Properly Seat an Option Module
Tighten the two captive screws.

For general information on option module interconnect wiring, refer to Chapter 3, titled
"Installation".
For more specific examples of option module interconnect wiring, refer to Appendix H.
For specific information on option module interconnect wiring on turn-key systems, refer to
the interconnect drawings supplied with the system.
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F: Auxillary Communications
Overview
The purpose of auxiliary communication output is to provide real-time values of measured
parameters to external equipment, such as computers, data loggers, etc. Some operator
commands can also be transmitted from an external device into a Series 2000 instrument.
Examples of these are ACKnowlege alarms, activate CAL1 or CAL 2 relays, perform or report
SELFTEST, and RESET certain values to zero.
There are two types of aux comm modules that can be installed in one of the option module slots
on the back of Series 2000 instruments:
RS232
RS485
Although an aux comm module can be installed in any of the option module slots, typically it is
installed in slot 4.
Note: Only one aux comm module can be installed in a Series 2000 instrument at one time.
Protocol Selection
There are three different protocols to choose from for aux comm:
PROTOCOL #1—the original, simplified comm protocol which is limited to the three basic
commands (SS, CS, and CD). This protocol is still a good choice when connecting only one
Series 2000 instrument to a computer. This protocol also allows for support of older, existing
field installations.
PROTOCOL #2—features of protocol #1 plus an expanded instruction set and more efficient
protocol for party line applications.
Continuous Mode—forces the instrument to automatically power up in the continuous scan
mode. The instrument acts like it has received a CS command. This is typically used when
the instrument is connected to a serial printer. The transmission interval is programmable via
the front panel, from 0.25 sec to 60 sec (in 0.25 sec increments).
Command List
SS (single scan)—request for a single transmission of all present values.
CS (continuous scan)—same as SS, only the transmissions will continue at a programmed interval
until an "ESCape" character is received or the instrument is reset.
CD (configuration dump)—request for a list of all configuration information. The answer returned
includes calibration constants, a channel list for the product (this list matches the channels
transmitted for SS and CS), alarm limits, and device numbers.
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ACK (acknowledge)—acknowledges alarms the same as pressing the front panel ACK button.
This silences all horns (internal and external), but does NOT clear the general purpose relays.
There is no response transmitted back from the instrument.
C1 (CAL 1)—turns on the "CAL 1" relay on the back of the instrument the same as activating the
relay from the front panel. The relay is cleared by transmitting an "ESCape" character to the
instrument. There is no response transmitted back from the instrument for either the C1 or the
"ESCape" signal.
C2 (CAL 2)—turns on the "CAL 2" relay on the back of the instrument the same as activating the
relay from the front panel. The relay is cleared by transmitting an "ESCape" character to the
instrument. There is no response transmitted back from the instrument for either the C2 or the
"ESCape" signal.
RS (reset)—resets the present value to zero. In the case of an LM2000, it resets the payout to
zero. In the case of the CI2000, the main net load and whip net load are set to zero (new "TARE"
value). There is no response transmitted back from the instrument.
ST (perform self test)—causes the instrument to perform the power up self test sequence. The
instrument is forced to reset and automatically runs the power-on self tests. There is no response
transmitted back from the instrument.
Note: The ST command causes a disruption in operation of the unit.
RT (report self test)—requests a transmission of the self test results that were stored at the last
self test. This does not trigger the instrument to perform a self test.
Delimiter Selection
In the SS and CS commands, the values returned are separated by a programmable character.
The choices are:
Comma
Space
Tab
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Protocol # 1
The basics of protocol #1 involve:
signing on to particular unit
receiving a response of self-test results from the unit
sending one of three commands (SS, CS, or CD)
receiving the response back from the instrument until you log onto another unit.
Once the communications wiring is properly connected, aux comm is initiated as follows:
Sign on to a particular Series 2000 unit by sending the following command:
where !! = sync characters

nn = device address number (drop address)
for sensor input units, the drop address = rotary switch setting (01–16)
for remote displays, the drop address = remote # + 16 (17–31)
for single device systems, the drop address is usually = 01
As a response to the "!!nn" command, the Series 2000 instrument will answer back with self test
results as follow:
where
A = one digit result of sensor unit CPU ram test
0 if passed
1 if failed
B = one digit result of sensor unit CPU PROM test
0 if passed
1 if failed
C = one digit result of sensor unit CPU EEPROM test
0 if passed
1 if failed
DDD = three digit error count for -15V power supply
000 if no errors
001–999 if any errors
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EEE = three digit error count for +15V power supply

000 if no errors
FFF = three digit error count for +24V power supply
000 if no errors
GGG = three digit error count for 3.84V reference
000 if no errors
HHH = three digit error count for A/D calibration errors
000 if no errors
JJJ = three digit error count for A/D data ready errors
000 if no errors
K = one digit result of display CPU RAM test
0 if passed
1 if failed
L = one digit result of display CPU PROM test
0 if passed
1 if failed
M = one digit result of display CPU EEPROM test
0 if passed
1 if failed
N = one digit result of display CPU bank PROM test
0 if passed
1 if failed
Now that the unit is on-line and active, it will respond to the commands SS, CS or CD that make up
Protocol #1.
SS Command
When you send the SS command to a Series 2000 instrument, you are asking it to respond with a
Single Scan of current values and alarm status information.
To send the SS command from a terminal or computer, simply type "SS" at the keyboard. The
instrument will respond with information in the following format:
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where
nn = sensor unit number (drop address) of the sensor unit sending this data
FF...F = current value in floating point format, including sign and decimal, right justified with
decimal position depending on channel precision. Current value and status information
provided for as many channels as listed in the response to the CD command, and in the
same order.
S = one character alarm status response
H for high-high alarm
h for high alarm
l for low alarm
L for low-low alarm
Space (blank) if no alarm condition
cr = carriage return
lf = line feed
CS Command
When you send the CS command to a Series 2000 instrument, you are asking it to respond with a
Continuous Scan of current values and alarm status information, at an interval you determine
when configuring the instrument.
To send the CS command from a terminal or computer, type "CS" at the keyboard. The instrument
will respond with information in the same format as a SS, only it will continue updating the
information until you press the Esc key on the keyboard.
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CD Command
When you send the CD command to a Series 2000 instrument, you are asking it to respond with a
Configuration Dump of the currently selected instrument. The instrument will respond with data in
the following format:
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where: Device number = drop address as defined in the command format

Sensor unit number = drop address of the sensor unit you’re viewing data from
CC...C = channel name, right justified with leading blanks
UU...U = units name, right justified with leading blanks
FF...F = current value in floating point format, including sign and decimal, right justified
with decimal position depending on channel precision
NN...N = integer format, right justified with leading blanks
lf = line feed
Protocol # 2
Protocol #2 is the preferred protocol for “party line” applications. In protocol #2, the sign on and the
request for data are part of the same command, thereby not wasting transmission bandwidth on
sending expanded self-test results over and over. Also note that a four character system status/
selftest status is added to the SS and CS response. If these results show a self-test failure, then
the more detailed self-test results can be requested. In addition, protocol #2 has a device address
wild card. For commands that require NO response, the device address can be replaced with “$$”,
which will cause all connected units to take the action the command specifies. Typical uses are
activating cal relays (C1) or acknowledging alarms (AK).
Once the communications wiring is properly connected, aux comm protocol #2 is initiated as
follows:
Sign on to a particular Series 2000 unit by sending the following command:
where !! = sync characters

AA = two character command (first characters must be alpha, i.e. SS, CD, etc.)
nn = device address number (drop address)
for sensor input units, the drop address = rotary switch setting (01–16)
for remote displays, the drop address = remote # + 16 (17–31)
$$ if the command applies to all devices (drop addresses) and requires
no response from the devices
lf = line feed
A list of valid commands and their expected response formats are described in the following sub
sections.
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CD Command
When you send the CD command to a Series 2000 instrument, you are asking it to respond with a
Configuration Dump of the currently selected instrument. The instrument will respond with data in
the following format:
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where: Device number = drop address as defined in the command format

Sensor unit number = drop address of the sensor unit you’re viewing data from
CC...C = channel name, right justified with leading blanks
UU...U = units name, right justified with leading blanks
FF...F = current value in floating point format, including sign and decimal, right justified
with decimal position depending on channel precision
NN...N = integer format, right justified with leading blanks
lf = line feed
SS Command
When you send the SS command to a Series 2000 instrument, you are asking it to respond with a
Single Scan of current values and alarm status information.
To send the SS command, simply type:
at the keyboard. The instrument will respond with information in the following format:
where:
nn = sensor unit number (drop address) of the sensor sending this data
FF...F = current value in floating point format, including sign and decimal, right justified with
decimal position depending on channel precision. Current value and status information
provided for as many channels as listed in the response to the CD command, and in the
same order.
S = one character alarm status response
H for high-high alarm
h for high alarm
l for low alarm
L for low-low alarm
Space (blank) if no alarm condition
XXXX = four character system status
CAL1 if the CAL1 relay is active, affecting current values
CAL2 if the CAL2 relay is active, affecting current values
0000 if no cal relay is active and all self tests passed
0001–9999 if no cal relay is active and there are any self test failures
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lf = line feed
CS Command
When you send the CS command to a Series 2000 instrument, you are asking it to respond with a
Continuous Scan of current values and alarm status information, at an interval you determine
when configuring the instrument.
To send the CS command, type:
at the keyboard. The instrument will respond with information in the same format as an SS, only it
will continue updating the information until you press the Esc key on the keyboard.
AK Command
This command acknowledges alarms.

Series 2000 instruments send no response back, but acknowledges all alarms.
C1 Command
Sending the C1 command turns on the CAL1 relay.

Sending an escape (Esc) character turns off the CAL1 relay.
C2 Command
Sending the C2 command turns on the CAL2 relay.

Sending an escape (Esc) character turns off the CAL2 relay.
RS Command
Sending the RS command resets a value to zero.

Series 2000 instruments send back no reply to this command, but do reset the current value to
zero for applicable channels (i.e. PAYOUT, TARE, etc.).
ST Command
Sending the ST command causes the system to reset, which then causes a self test to occur.
Series 2000 instruments send back no reply to this command.
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RT Command
As a response to the "RT" command, the Series 2000 instrument will answer with self test results
as follows:
where:
A = one digit result of sensor unit CPU ram test
0 if passed
1 if failed
B = one digit result of sensor unit CPU PROM test
0 if passed
1 if failed
C = one digit result of sensor unit CPU EEPROM test
0 if passed
1 if failed
DDD = three digit error count for -15V power supply
000 if no errors
EEE = three digit error count for +15V power supply
000 if no errors
FFF = three digit error count for +24V power supply
000 if no errors
GGG = three digit error count for 3.84V reference
000 if no errors
HHH = three digit error count for A/D calibration errors
000 if no errors
JJJ = three digit error count for A/D data ready errors
000 if no errors
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K = one digit result of display CPU RAM test

0 if passed
1 if failed
L = one digit result of display CPU PROM test
0 if passed
1 if failed
M = one digit result of display CPU EEPROM test
0 if passed
1 if failed
N = one digit result of display CPU bank PROM test
0 if passed
1 if failed
Aux Comm Response Times

In certain applications, response time of the instrument to aux comm commands can be an
important issue. The following guidelines must be considered when writing software to
communicate with Series 2000 instruments.
SS (single scan) Command

Command processing overhead is measured from the time the last character of the command is
received to the time the first character of the reply is transmitted. This averages around 60ms, but
occasionally varies upward to as much as 400ms if other system events are waiting to be
processed when the command is received.
Reply transmission time must be added to the command process time to arrive at the overall time
for receiving full response for the command. This time will depend on baud rate and the number of
channels in the response. Below is an example of how this is calculated for 9600 baud, and may
be used to determine transmission time for other baud rates.
Example:
At 10 bits per character, character transmission time is about 1ms (10/9600).
At 10 characters per channel, channel transmission time is 10ms.
Therefore, total response time (command process + transmission time) for 10 channels is:
Typical = 60 + 100 = 160ms
Practical maximum = 400 + 100 = 500ms
In addition, each transmission includes a header (device number) and a trailer (status, [cr], [lf],
etc.) which adds approximately 10 more characters.
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C1 (Cal1) Command
Process time for this command ranges from 3ms to about 400ms. This command does not require
any response to the host. Also, the process time for this command is applicable to all other
commands that do not require any response (C2, AK, RS). Because this type of command is
transmitted infrequently, it is recommended to wait >500ms after transmitting before transmitting
any additional command.
CD (Configuration Dump) Command

Complete response time (process + transmission time) for this command is to be in the range of
1.25–1.5 seconds for 7 channels.
Conclusions on Response Time

Based on the data above, the following timing criteria is recommended for host communication
software:
When polling devices with the SS command for their current values, send the next poll when the
complete response has been received. In the event that no response is received for 600ms,
depending on channel count and baud rate, a time-out should abort the current poll and the next
poll may be issued. Regardless, if a time-out is used, collisions may occur if the instrument
response overlaps the next poll and the two devices are trying to transmit at the same time. This
type of collision will cause a UART error. Therefore, the host software should discard the response
if there are any UART errors, and either retry the same device until some maximum retry is
reached, or move on the next device.
When issuing any command like C1, which does not require any response, the next command
should not go out until a no-response time-out occurs.
When requesting a configuration dump with the CD command, sufficient time should be allowed to
receive the complete response. As this time depends on the total number of channels (16 max),
and it is only required once on start up, it is recommended that a 5 second time-out be used with
this command.
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G: Networking
Overview
Networking is used to operate a group of up to 16 Series 2000 units together for the purpose of
having remote displays, multiple displays, etc. This communication port is standard on all Series
2000 instruments through the TB3 connections on the back of each unit.
There are two different types of stations in a network:
Sensor input unit
Remote display unit
Sensor Input Unit

Sensor input units come in two forms: those with displays, and those without displays.
Sensor Input Unit With Display

Displays on these units can only show data for the sensors that are connected to the unit. The
display, therefore, cannot act as a remote display for other sensors.
Sensor Input Unit Without Display (DAQ)

Often referred to as remote data acquisition units (or DAQ’s), these must have remote displays
connected to them in order to calibrate or configure the unit.
There can be a maximum of 16 sensor input units in a network, but the total number of instruments
in a single network cannot exceed 16.
Remote Display
Remote displays cannot read signals directly from sensors. Remote displays must get their
information from the network. They can, however, drive relays and option modules. Every remote
display can be configured (via the front panel) to act as a display for any sensor input unit in the
network. Remote displays have access to all calibration and configuration features just like a local
display on a sensor input unit. There can be a maximum of 15 remote displays in a network.
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Sensor Input Unit Setup

Using a small flat head screwdriver, set the rotary address switch on each sensor input unit
to a unique number. Refer to Figure G.1. Typically, you will want to set them to sequential
numbers starting with number one.
Rotary
Address V+ S+ S- V- V+ S+ S- V- V+ S+ S- V- V+ S+ S- V-
Switch TB4-ANLG1 TB5-ANLG2 TB6-ANLG3 TB7-ANLG4
ADJUST
CONTRAST
RESET
ADDR + A - CHS A+ A- B+ B- M2 M1 G2 G1 M2 M
TB8-POS PWR TB9-POS SIG TB13-RLY4 TB
Figure G.1: Rotary Address Switch Location on Rear Panel of Instrument
Power up the unit, and verify that the unit is configured as a “sensor input unit” in the
Network Setup screen. See Chapter 5, titled "Configuration and Calibration" for more
information.
For units with displays, look in the Network Setup screen to see what switch setting the unit
has. Always use this number and ignore what is printed on the switch itself.
For remote data acquisition units (sensor input units without displays), you must read the
numbers printed on the rotary switch body. The switch is printed with hexadecimal numbers,
so refer to the following table to determine what hexadecimal number corresponds to what
switch setting:
The setting of the rotary switch becomes the unit number when referenced by any remote
displays. For example, on LM2000 systems, this rotary switch sets the WINCH#. On CI2000
systems, this rotary switch sets the CRANE#.
Remote Display Unit Setup

In the Network Setup screen, set all remote displays to a unique number, i.e. "Remote
Display #1" or "Remote Display #2"…"Remote Display #15".
Select a sensor unit number whose data is to be shown on the remote display by pressing
the button labeled SCREEN in the main operators screen.
Highlight "Select ______" (winch, crane, etc.) and press the select key.
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Select the number of the sensor unit you chose in step 2 above.
Note: If the data is ever corrupted, the remote display will have to load all new default
values. The rotary switch setting of the remote display will be used as the default unit
number for that unit. Therefore, it is suggested that the switch setting of the remote display
match that of the sensor unit to be displayed remotely.
Network Examples
The following examples are diagrams of various network examples. The switch settings and
network setup parameters are shown in each example.
Note: Please note that the switch setting listed in the diagram refers to the switch setting as
displayed in the network setup screen, not what is printed on the switch body itself. For
more information on switch settings, refer to "Sensor Input Unit Setup" on page 132.
Network #1—Remote DAQ to Remote Display

This example has one remote data acquisition unit connected to one remote display. This is the
most basic kind of network.
Figure G.2: Remote DAQ to Remote Display
Network #2—Sensor/Display to Remote Display

This example has one sensor/display unit connected to one remote display. This is the same as
Network #1, but the sensor unit has its own display.
Figure G.3: Sensor/Display to Remote Display
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Network #3—DAQ to Multiple Remote Displays

This example has one remote data acquisition unit connected to multiple remote displays. Any
remote display can be used to calibrate/configure the remote data acquisition unit.
Figure G.4: DAQ to Multiple Remote Displays
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Network #4—Sensor/Display to Multiple Remote

Displays
This example has one remote display connected to a sensor/display unit. This is the same as
Network #3, but the sensor unit has its own display.
Figure G.5: Sensor/Display to Multiple Remote Displays
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Network #5—Remote Display to Multiple DAQs

This example has one remote display connected to several remote data acquisition units, each
hooked to separate sensors. The remote display can be used to calibrate/configure any one
remote data acquisition unit at a time; the particular remote daq unit is selected via the remote
display’s front panel “screen” button.
Figure G.6: Remote Display to Multiple DAQs
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Network #6—Remote Display to Multiple

Sensor/Displays
This example has one remote display unit connected to multiple sensor/display units. This is the
same as Network #5, except each sensor has its own local display.
Figure G.7: Remote Display to Multiple Sensor/Displays
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Network #7—Multiple Remote DAQs to Multiple

Remote Displays
This example has several remote data acquisition units connected to several remote displays,
each display showing data from a different, single DAQ unit.
Figure G.8: Multiple Remote DAQs to Multiple Remote Displays
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Network #8—Multiple Sensor/Display Units to

Multiple Remote Displays
This example has multiple remote displays connected to multiple sensor/display units. The is the
same as Network #7, except each sensor unit has its own local display. Any remote display can be
used to calibrate/configure any one sensor/display unit. To choose which sensor unit a remote
display will show, you must use the “screen” button on the remote display.
Figure G.9: Multiple Sensor/Display Units to Multiple Remote Displays
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Networking and Aux Comm

Standard networking is carried out through the RS-485 interface provided by TB3 on the back of all
Series 2000 instruments. The data is in a proprietary binary form, making it difficult to use outside
the network. In addition to the standard networking communications, it is possible to have auxiliary
communications through an aux comm option module installed on the back of the unit.
Aux comm modules use standard ASCII data that is easier to work with on any terminal or PC,
allowing the user to create programs that speak the “language” of aux comm. Both of these
network communications can be used simultaneously. For more information on aux comm
modules, see Appendix F.
Network/Aux Comm Examples

The following examples are diagrams of various network/aux comm examples. The switch settings
and network setup parameters are shown in each example.
Note: Please note that the switch setting listed in the diagram refers to the switch setting as
displayed in the network setup screen, not what is printed on the switch body itself.
Network #9—Multi. Sensor/Display to Multi.

Remote Displays w/ Aux Comm
This example has multiple sensor/display units connected to multiple remote displays with all
remote displays connected to a PC. The host PC addresses the remote displays as numbers 17–
32, where remote display #1 is address 17, remote display #2 is address 18, remote display #3 is
address 19, etc.
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Figure G.10: Multiple Sensor/Display to Multiple Remote Displays w/ Aux Comm
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Network #10—Multi. Sensor/Display w/ Aux

Comm to Multi. Remote Displays
This example has multiple sensor/display units connected to multiple remote displays, with all
sensor/display units connected to a PC via aux comm. The host PC addresses the sensor/display
units by their rotary switch settings, where the unit with a switch setting of 1 is addressed as 01,
unit with switch setting 2 is addressed as 02, and so on.
Figure G.11: Multiple Sensor/Display with Aux Comm to Multiple Remote Displays
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H: Interconnect Example Drawings
Overview
The following drawings show wiring examples for various types of enclosures and equipment
setups. Use these drawings as a reference when wiring Series 2000 systems.
Sheet 1 (221117-001)—SC103 with shuntcal connected to a load cell and an SP102 payout
sensor.
Sheet 2 (221117-002)—2078 signal conditioner (and 2077 motherboard) with voltage
substitution connected to an SP102 payout sensor.
Sheet 3 (221117-003)—2078 signal conditioner (and 2077 motherboard) with shuntcal
connected to an SP102 payout sensor.
Sheet 4 (221117-004)—SC103 and prox sensors in a hazardous environment, and the
display in a safe area.
Sheet 5 (221117-005)—SC103 without shuntcal connected to a load cell and an SP102
sensor.
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I: Illustrated Parts Lists
Overview
The appendix contains miscellaneous drawings and parts lists for LM2000 products. The drawings
are listed in the order that they appear at the end of this appendix.
Series 2000 Catalog Drawing (drawing # 220921)
Main Assembly Drawing (drawing # 220870)
Dashmount Enclosure Kit (drawing # 220898)
Remote Data Acquisition Enclosure Kit (drawing # 220930)
Installation Kit (drawing # 220925)
The following sections describe how to choose the correct part numbers for any configuration of
LM2000.
Warning: EXPLOSION HAZARD - Substitution of components may impair

suitability or Class I, Division 2.
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Locating Model Information

The following subsections show how to find a part number to order a replacement part for LM2000
products. First, you should try to locate the model code. Look on the rear panel of the unit as
shown in Figure I.1.

Assembly part number

and serial number are RLY1
located on the exterior
RLY1
left side of the cover.
RLY2
RLY2
RLY3
RLY3
RLY4
+ -
ADJUST
CONTRAST
RESET + A - CHS A+ A- B+ B- M2 M1 G2 G1 M2 M1 G2 G1
Figure I.1: Location of Model Code on Rear Panel
There are four different categories you can fall into:

You have the model code.
You don’t have the model code, but you know what type you have.
You have the model code, but it contains -E#### (where #### represents a four digit project
code).
You don’t have the model code, and you don’t know what type you have.
If you fall into categories 1 or 2, you should continue with the following sub-sections to find the
required part numbers.
If you fall into categories 3 or 4, you should contact the factory for more information about your
units and their replacement parts.
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Model Code
Each LM2000 has a model code associated with it. Once this model code has been located, you
can use it to determine the part numbers of each field replaceable part.
The model code will look like the following example:
LM2-1A-1234-AABC where
what’s in option socket 1
enclosure
type
LM2-
what’s in relay socket 4

Figure I.2: Example of a LM2000 Model Code
Once you have located the model code, refer to the catalog drawing as follows to determine the
necessary part numbers. The catalog drawing is the first of the large Z-folded pages at the end of
this appendix. The catalog drawing images on the following pages are too small to read and are for
mapping purposes only. Refer to the full size drawing at the end of this appendix when necessary.
What Type of LM2000 is it?

If the unit is marked with a model code, the first character after LM2- tells you what type of unit it is
(single axis, dual axis, etc.). If the unit isn’t marked, but you know the type, you can skip directly to
the table listing the parts, otherwise, use the catalog drawing to figure out the type. Refer to Figure
I.3
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Figure I.3: Model Type on Catalog Drawing
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Find numbers listed below and refer to the circled numbers in drawing 220870-1XXX.
Core Assembly Components on Display Units (220870-1XXX)
Find # Part Number Description Number

Required
1 220899-001 Bezel Mod, Series 2000 1
2 935422-001 LCD Module, 240 X 128 1
3 999328-028 Spacer, #6 X .50, .25 RND 6
220840-002 Type 1 PCBA, Main, 4 Channel, 1-Axis

4 220840-003 Type 2 PCBA, Main, 4 Channel, 2-Axis 1
220840-006 Type 5 PCBA, Main, 4 CH, Polynomial
5 999202-120 Standoff, F/F, 6-32 X .75 6
6 220837-001 PCBA, Field Wiring, LM2000 1
7 220854-002 Cover, Series 2000, 4 Channel 1
8 999314-100 Washer, Lock, INT, #6, SST 6
9 2850-06080 Screw, 6-32 X .50 PNHD, S 6
10 999449-569 Screw, 6-32 X .38, PNH, PHL 2
11 999269-002 Washer, Lock, EXT, #6, SST 2
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Core Assembly Components on Remote Data Acquisition Units (220870-
2XXX)

Required
1 220920-001 Sub-Panel, RMT Data ACQ 1

5 999202-120 Standoff, F/F, 6-32 X .75 6
6 220837-001 PCBA, Field Wiring, LM2000 1
7 220854-002 Cover, Series 2000, 4 Channel 1
9 2850-06080 Screw, 6-32 X .50 PNHD, S 6
10 999449-569 Screw, 6-32 X .38, PNH, PHL 2
11 999269-002 Washer, Lock, Ext, #6, SST 2
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Core Assembly Components on Stainless Steel Display Units (220870-
3XXX)

Required
221105-001 Res Kit, S-2000, 50K, 100 1
1 221359-001 Kit, SS Bezel W/Encl 1
2 935422-001 LCD Module, 240 X 128 1
3 999328-028 Spacer, #6 X .50, .25 RND 6

5 999202-120 Standoff, F/F, 6-32 X .75 6
6 221075-001 PCBA, Field Wiring, Strain Gage 1
7 220854-003 Cover, Series 2000, Strain Gage 1
9 2850-06080 Screw, 6-32 X .50 PNHD, S 6
10 999449-569 Screw, 6-32 X .38, PNH, PHL 2
11 999269-002 Washer, Lock, Ext, #6, SST 2
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What Kind of Enclosure?
Figure I.4: Enclosure Information on the Catalog Drawing
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Series 2000 Dashmount Enclosure Assembly (220898-001)

Required
1 220907-001 ENCL WMT, SERIES 2000 1
2 220908-001 U-BRACKET, ENCL, SERIES 2000 1
3 999531-007 STANDOFF, M/F, 6-32 X 2 6
4 2800-56081 PHMS, 6-32 X .50 PHL 6
5 2802-26000 WASHER, LOCK, #6, SS, INST 6
6 220924-001 SPACER, .281” X 1.00” X .50 2
7 2809-5700 KNOB, 1/4-20 UNC, W/FEMALE 2
8 955704-001 CONN, CORD, .25-.40, 1/2” *
9 955704-002 CONN, CORD, .38-.62, 1/2” *
10 963700-001 LOCKNUT, CND, .50” NPS *
11 2530-00003 RING, SEALING 0.5” *
12 2173-00012 PLUG, CAP, RUBBER, 0.5” *
13 1691-00001 VCI EMITTER # VCI101 1
14 230106 PLUG, CORD GRIP 1/2” *
15 2590-00101 PLUG, CORD GRIP, 1/4” *
*Varies with each application
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Series 2000 Remote DAQ Enclosure Assembly Box (220930-001)

Required
1 220919-001 ENCL ALTRN, SERIES 2000 1
2 955704-001 CONN, CORD, .25-.40, 1/2” *
3 955704-002 CONN, CORD, .38-.62, 1/2” *
4 2530-00003 RING, SEALING 0.5” *
5 963700-001 LOCKNUT, CND, 0.5” *
6 2173-00012 PLUG, CAP, RUBBER, 0.5” *
7 1691-00001 VCI EMITTER # VCI101 1
8 220321 LABEL, LOGO, TRI-COLOR 1
9 230106 PLUG, CORD GRIP, 1/2” *
10 2590-00101 PLUG, CORD GRIP, 1/4” *
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Series 2000 Installation Kit (220925-001)

Required
1 955704-001 CONN, CORD, .25-.40, 1/2” *
2 955704-002 CONN, CORD, .38-.62, 1/2” *
3 963700-001 LOCKNUT, CND, 0.50” NPS *
4 2530-00003 RING, SEALING 0.5” *
5 J10480A-14 SEAL, HOLE, .50” CND *
6 2801-03000 NUT, HEX, 3/8-16 SST *
7 2802-03000 FW, SS, 3/8” *
8 2802-19000 LW SPLIT C 3/8, 18-8 *
9 2800-49206 HHCS, 3/8-16 X 1/2, 18-8 *
10 2800-49205 SCREW, 3/8-16 X 1.0, HEX *
*Varies with each application
Which Relays are Installed?

Each relay has a manufacturer part number located somewhere on the outside case of the relay.
This number can be cross referenced to the M/D TOTCO part number using the catalog drawing,
or the model code (if known).
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Figure I.5: Relay Information on the Catalog Drawing
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What Option Modules are Present?

Simply look at the option module itself. Each option module has its part number printed on it.
Figure I.6: Option Module Information on the Catalog Drawing
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Series 2000 Instruments

Installation, Calibration, and Operation

REFERENCE REFERENCE DESCRIPTION

E 04.17.2007 Revised per EC #: 69784-01

Revision Change Description

Chapter 4: Normal Operation

Chapter 5: Configuration and Calibration

Appendix B: Alarms and Relays

Appendix C: Strain Gauge Sensor Calibration

Appendix D: Load Cell Troubleshooting

Appendix E: Option Modules

Appendix F: Auxillary Communications

Appendix H: Interconnect Example Drawings

Appendix I: Illustrated Parts Lists

To avoid injury to personnel or equipment damage, carefully observe requirements outlined

General System Safety Practices

 Isolate energy sources before beginning work.

Failure to conduct routine maintenance could result in equipment damage or injury to

Proper Use of Equipment

 The alarm light can display three levels of alarm:

Figure 2.2: Front Panel

Figure 2.3: Back Panel

Figure 3.1: Cutout

Caution: Installation of Series 2000 Instruments in a Class I, Division 2, Groups C and D

Mount the unit as follows:

Heavy Duty Stainless Steel Bezel Option

Remote Data Acquisition

Figure 3.2: Back Panel

Warning: Explosion Hazard - Do not disconnect equipment unless power has

TB1-12/24VDC (Power Input)

Figure 3.3: Input Power

TB2-PWR OUT (Power Output)

OFF OFF ON/OFF

TB2 TB2 TB2

CHASS CHASS CHASS

Instrument 1 Instrument 2 Instrument 3

TB3-RS485 (Network Communication)

TB4-ANLG1 (Analog Input #1)

Figure 3.6: Two Wire Analog Input

PWR IN V+ (+24V Output)

4-Wire +SIG S+ (+Signal In)

Common V- (+24V Return)

Figure 3.7: Four Wire Analog Input

TB5-ANLG2 (Not Used)

Figure 3.8: +5 VDC Sensor Wiring

+ +24 VDC Output

Figure 3.9: +24 VDC Sensor Wiring

+ +12 VDC Output

Figure 3.10: +12 VDC Sensor Wiring

TB9-POS SIG (Payout Sensor Signal)

Figure 3.11: TTL Sensor Wiring

Open Collector (NPN) Sinking (Switch to Ground)

Figure 3.12: Open Collector (NPN) Sensor Wiring

Open Collector (PNP) Sourcing (Switch to +24 VDC)

Figure 3.13: Open Collector (PNP) Sensor Wiring

Figure 3.14: NAMUR (Proximity) Sensor Wiring

TB10 Through TB13 (Relay Option Ter minal

Connection Rating Mfg. Part # M/D Totco Part #

Figure 3.15: Alarm Interconnects and Relay Configurations

MD Totco Series 2000 Instruments Installation, Calibration, & Operation

MD Totco Series 2000 Instruments Installation, Calibration, & Operation

MD Totco Series 2000 Instruments Installation, Calibration, & Operation

Isolate energy sources before beginning work.

The alarm light can display three levels of alarm: