This article discusses six common issues that engineers face during data acquisition recorder testing, covering configuration, testing, communication, display, and storage. It provides practical solutions for handling typical abnormalities in data acquisition tests and will be continuously updated to ensure the latest insights.
The process begins with setting up the interface of the data acquisition recorder, whether through the DP100 screen or a PC via a web browser. Users must select either automatic or manual configuration under the "Board Configuration" section. Once this is done, parameters such as AI channels can be adjusted according to specific test requirements, as illustrated in Figure 2.
Figure 2: Channel Settings
**First, Configuring the Data Acquisition Module**
Both DP100 and DM100 support up to 200 channels. When configuring, it's important to consider the test requirements. There are three key points to note:
- The DM100 host requires a power module, while the DP100 does not.
- If the DP100 has more than 30 channels (or 3 modules), an expansion module must be added, which also needs a power module for operation.
- For large-scale tests with over 100 channels, understanding the test environment is crucial to ensure proper configuration of expansion modules, as shown in Figure 3.
Figure 3: Oven Line Temperature Test
**Second, Interface Display Issues – Positive Overflow or Breaks**
As shown in Figure 4, the interface may display positive overflow, positive break, or negative break on channels X0101/X0102/X0103. These issues typically arise from disconnected, loose, or faulty thermocouples. To resolve them, checking the terminal connections is essential.
Figure 4: Broken Thermocouple Display
The settings for these errors are displayed in Figure 5. Options include:
- **"Do Not Use"**: When the sensor is broken, the value is shown as "positive overflow."
- **"Positive Display"**: When the sensor fails, the reading is fixed at the positive overflow value, showing "positive break."
- **"Negative Display"**: When the sensor is broken, the reading is fixed at the negative overflow value, showing "negative break."
Figure 5: Breaking Setting
**Third, Temperature Rise Test**
1. **Main Steps**
As seen in Figure 7, channel X0002 displays the temperature rise. The steps are as follows:
- Under "AI Channel," enter "Range" and set the operation to Delta.
- Set the reference channel to X0001, as shown in Figure 6.
Figure 6: Delta Operation Settings
In the "Overall Interface," the X0002 display shows the temperature rise of 7.6°C (X0001 is suspended in the air, representing ambient temperature). When holding the 2-channel thermocouple, X0002 rises to the hand temperature minus the ambient temperature, as shown in Figure 7.
Figure 7: Delta Operation Temperature Rise Display
2. **Main Benefits**
This method eliminates the need for engineers to manually calculate temperature rise using Excel after exporting data, improving efficiency. Additionally, real-time accuracy is enhanced due to fluctuations in ambient temperature.
**Fourth, Information Tags on Trend Charts**
As shown in Figure 8, in the display settings, users can select "Information Setting" to define start and end tags for information numbers 1 and 2.
Figure 8: Tag Information Settings
In Figure 9, clicking on a desired mark in the trend chart allows users to assign specific information to it.
Figure 9: Information Tag
These tags function similarly to oscilloscope markers, making it easy to locate marked points of interest quickly.
**Fifth, Communication in Data Acquisition**
There are three main types of communication between the data acquisition system and external devices:
- **Communication with the "Zhiyuan Power Meter":** Uses SCPI commands over Ethernet. For detailed steps, refer to the sixth point about connecting the power meter.
- **Communication with other devices:** Uses Modbus over Ethernet to read values from device registers.
- **Communication with other devices:** Uses Modbus via serial ports (DP100 supports RS485/422/232; DM100 supports RS485/422).
The general interface settings are shown in Figure 10.
Figure 10: Data Acquisition and External Device Communication Settings Interface
When using Modbus over Ethernet (TCP/IP), one device acts as the client and the other as the server. When using Modbus via serial ports, one is the master and the other is the slave.
**Sixth, Connecting the Data Acquisition System to Our Power Meter**
1. **Main Steps**
- Ensure the computer, data acquisition, and power meter are on the same network segment. Connect each device to a router or switch using network cables.
- Enter the IP address in the browser, navigate to the connection interface, and select "Network Settings" under "Settings." Then, go to "Power Meter Basic Settings" and enable the power meter, as shown in Figure 11.
Figure 11: Power Meter Function Enabled
- Select "Power Meter Server Settings," turn on the server, set the server IP (i.e., the power meter IP), and choose the corresponding power meter model, as shown in Figure 12.
Figure 12: Power Meter Server Settings
- Go to "Power Meter Data Distribution Settings," select the server number from the previous step, and configure the "Data Group Name," "Data Name," "Exponential Zoom," and "Communication Channel" (used to display the value read from the slave power meter), as shown in Figure 13.
Figure 13: Power Meter Data Distribution Settings
- Switch to the "Communication Channel" tab in the "Settings" interface and set the "Upper/Lower Limit" in the "Range" section, as shown in Figure 14.
Figure 14: Communication Channel Settings
- After setup, switch to the "Overview" interface of the "Data" section. You can now see the power count values collected by the data acquisition system on the corresponding communication channels (e.g., C001, C002), as shown in Figure 15.
Figure 15: Communication Channel Value Display
- Note: Since the data acquisition and power meter communicate via SCPI commands over a network cable, it’s necessary to disable the Modbus function on the power meter (via the interface button).
2. **Main Benefits**
This setup enables convenient comparison of voltage, current, and power with temperature readings. For example, you can check if the temperature at a specific point exceeds limits at a given power level.
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