BATCH CONTROLLERS MODEL 414A November 1995
CONTENTS 1. Introduction 1.1 Model Number Designation 3 4 2. Specification 5 3. Operation 7 3.1 Front Panel Operation 3.2 Batch Operations 3.2.1 Control Relay Outputs 3.2.2 Signal Timeout 3.2.3 End of Batch 3.2.4 Auto Restart 3.2.5 Automatic Overrun Compensation 3.3 Calculation of Rate and Total 3.3.1 Analog Input 3.3.2 The Cutoff Point 3.3.3 Filtering 3.4 Total Conversion 3.5 The Output Pulse and Flow Alarm 4. Options 4.1 The RS232/422/485 Interface Option 4.1.1 Hardware 4.1.
6. Input Circuits 6.1 The Signal Input 6.2 Remote Switch Inputs 7. Installation 7.1 General 7.2 Wiring Designations for the Model 414A 8. Trouble Shooting 8.
Introduction 3 1. INTRODUCTION The Model 414A Batch Controller accepts analog flow signals and automatically controls the batching of fluids via a one or two stage control valve. The instrument is extremely flexible and easy to operate, with a four key, front panel operation that enables the batch quantity to be set, and batches to be started or stopped.
4 Introduction 1.1 MODEL NUMBER DESIGNATION The Model number of an instrument describes which input and output options are installed and the AC mains voltage rating. Model 414 A. 1 0 E B B for Backlite C for Conformal Coating E for 220/240 VAC A for 110/120 VAC D for DC Power Only Options 0 for no option 2 for RS232/422/485 Mounting 1 for panel mounting 2 for field mounting 3 for explosionproof The Model Number of the instrument is displayed on first entering the Calibration Mode (see Section 5).
Specification 5 2. SPECIFICATION General Display: Display Update Rate: Transducer Supply: Power Requirements: Operating Temperature: Dimensions: Cutout: 6 digit LCD. 0.7" (17.8mm) high digits. 0.25 seconds. 8-24VDC field adjustable. 50mA maximum. 11.5 to 28.5 volts DC. 130 mA typical current (no options). AC Mains: Set internally to 95-135 VAC or 190-260 VAC. 0 to 55°C standard. 5.7" (144mm) wide x 2.8" (72mm) high x 7.0" (178mm) deep. 5.5" (139mm) wide x 2.6" (67mm) high.
6 Specification Relay Outputs Maximum Switching Power: 1250VA. Maximum Switching Voltage: 250VAC, 30VDC. Maximum Switching Current: 5 Amps. Pulse Output Pulse Width: Maximum Duty Cycle: Output: Scaling: 10mSec (negative going pulse). 49 pulses per second. An open collector transistor will sink 100mA. The pulse output is scaled and outputs one pulse each time the accumulated total increments.
Operation 7 3. OPERATION The Model 414A Batch Controller uses a low power CMOS microprocessor to perform all control functions and calculations. The instrument is fully programmable with all operating parameters and calculation constants user programmable. (See Section 5 entitled "Calibration" for information on programming.) All parameters and constants are stored in a non-volatile memory which retains data without battery backup for a minimum of 10 years.
8 Operation 3.1 FRONT PANEL OPERATION The four key operation of the Batch Controller is straight forward. SETTING THE BATCH QUANTITY The Batch quantity is programmed as follows: Switch Action Display Comments Press BATCH SET Batch "Batch" is displayed for one second followed by the batch quantity last entered. The Batch Set LED lights. "1" 2345 The most significant digit flashes indicating that it can be changed. Press "2" 2345 Pressing the DISPLAY key will increment the digit.
Operation 9 The Batch quantity can only be set while the instrument is in non-operational state such as when the batch is complete, or if the batch process has been interrupted. However, the Batch key can be pressed while in the run state and the Batch quantity checked. All digits will flash to signal the quantity cannot be changed. STARTING A BATCH To start the process the RUN key is pressed.
10 Operation DISPLAYED INFORMATION The display will normally show the Batch Total, which is the total count for the current batch and is reset on each new batch. The DISPLAY key can be used to display the following additional information: Rate On the first press of the DISPLAY key, the display shows RATE for one second followed by the flowrate. Accumulated Total On the next press of the DISPLAY key, the display shows ACC for one second followed by the actual total.
Operation 11 3.2 BATCH OPERATIONS The Batch Control functions can be programmed, during Calibration, to operate in one of two ways. 1. At the end of the batch, the STOP key must be pressed to reset the Batch Total. (This must be done before another batch can be started.
12 Operation 2. If Automatic Reset is programmed, a new batch is commenced each time the RUN key is pressed. Batch Quantity Reached PAUSE Run Stop Run Run Count Down Count Up Relay 1 Relay 2 Start Time Prestop Quantity End of Batch Auto Restart Time End of Batch The Batch Controller can also be programmed, during Calibration, to either count up from zero on each batch, or to count down from the preset batch quantity.
Operation 13 3.2.1 Control Relay Outputs The two output relays can be set up to control a single valve or a dual valve with slow stop and/or slow start. Alternatively, the second relay can be used to control a pump. The relay operation is shown on the previous two pages. A time delay between the Start and the time when relay 2 energises can be programmed to provide a soft startup. The delay can range from 0 (no delay) to 79 minutes and 59 seconds. A Prestop quantity (ie.
14 Operation 3.2.2 Signal Timeout The Signal Timeout period defines a time interval which is used to detect if the flow has stopped. If there is no signal input for a time greater than the Signal Timeout period, the flow is deemed to have stopped. A Signal Timeout period has two functions: To detect the loss of signal midway through a batch when the relays are energised. In this case, the Batcher will enter a Flow Alarm condition and de-energise the relays.
Operation 15 3.2.3 End of Batch An End of Batch is defined as being when the Batch Quantity is reached, the flow has stopped and the Signal Timeout period has expired. If the Signal Timeout is set to zero, the End of Batch is defined as being when the Batch Quantity is reached, regardless of whether the flow has stopped. The Batch Controller cannot be reset or restarted until the End of Batch and similarly, for an RS232/422/485 interface, data will not be output until the End of Batch has been determined.
16 Operation 3.2.4 Auto Restart The Batch Controller can be programmed to continually repeat the batch process. This mode of operation is selected during the programming procedure. The process is started by pressing the RUN key whereby the normal batch operation is commenced. After reaching the End of Batch (see section 3.2.3), the Batch Controller will then wait for a pre-programmed period before automatically resetting and starting the batch process once again.
Operation 17 3.2.5 Automatic Overrun Compensation The Batch Controller can be programmed to automatically compensate for any overrun at the end of a batch. Typically, this could be due to the slowness of a valve to close or a pump to stop pumping on receiving a signal from the Batch Controller. The result is that the batch quantity will always read higher than the batch quantity set.
18 Operation 3.3 CALCULATION OF RATE AND TOTAL 3.3.1 Analog Input The flowrate, R, is calculated as follows: or R = SA + C if the linear relationship is selected. R =S A +C if a square law relationship is selected. R = SA n + C if an open channel relationship is selected. where A= the input value. S = the span. C= the zero. n = a variable power which can be programmed between 0 and 9.999. At the minimum input (ie. 4mA, 0mA, 1 Volt or 0 Volts), A = 0, and at the maximum input (ie.
Operation 19 3.3.2 The Cutoff Point Because many transducers do not always exactly transmit 4mA (0mA, 1V or 0V) when they are at zero rate, it is often necessary to define a rate below which no integration takes place. This is termed the cutoff point and is programmed as a percentage of the Span, S. For example, if S = 2200 kg/min with an offset of 100 kg/min in a square law system, and the cutoff point is set at 20.
20 Operation 3.3.3 Filtering Frequency fluctuations caused by pulsating flow through a flowmeter, often makes the Rate impossible to read with any precision. The Batch Controller has a digital filter which will average out these fluctuations and enable the Rate to be read to four digit accuracy. The ability to select a suitable filtering level means that highly accurate and stable readings can be obtained without excessive lag.
Operation A 90% 99% 1 0 0 2 1 2 4 2 4 6 3 6 10 5 11 15 8 17 20 11 22 25 14 28 35 20 40 45 25 51 60 34 69 75 43 86 90 52 103 99 57 113 Table 1 - Response to a step Input (in seconds). Note that if A is set to 1 there is no filtering of the input signal.
22 Operation 3.4 TOTAL CONVERSION The Total Conversion feature enables the rate to be displayed in one engineering unit (eg. gallons/minute) and the totals to be displayed in another engineering unit (eg. barrels). The Scaling Factor is always programmed in the unit relating to Rate, and the Total Conversion constant is a division factor which can be used to convert the totals to the different unit. The Total Conversion factor affects the net, accumulated and gross totals and is limited between 0.
Operation 23 3.5 THE OUTPUT PULSE AND FLOW ALARM An OUTPUT PULSE is available on terminal 10 for driving remote counters and produces a pulse each time the Accumulated Total increments by one digit. For example, if the Accumulated Total has a resolution of 0.01 litres, a pulse is produced each 0.01 litres. The pulse is a current sinking pulse of approximately 10mSec produced by an open collector transistor.
24 Operation Connection of Output Pulse and Flow Alarm are as follows: Relay or Impulse Counter 5.6 ohms 33V Zener 12 DC Supply Driving an External Relay or Impulse Counter DC Supply Out (8-24V) 11 External Load Resistor 10K Logic Input 5.
Options 25 4. OPTIONS 4.1 THE RS232/422/485 INTERFACE OPTION With this option installed, the circuits for both the RS232 and RS422/485 are provided as standard. They can be used to interface to both printers and computers and a number of standard protocols are built into the instrument. 4.1.1 Hardware The following diagram provides an overview of the RS232/RS422/485 communications hardware.
26 Options 4.1.2 Multipoint Communication Multipoint Communication is a system whereby a number of instruments can be addressed over a dual twisted pair interface. Up to 32 instruments can be connected to a common bus using the RS422 and RS485 interfaces as shown below. To convert the RS422 interface to an RS485 interface, the RS422 (-) Data In Terminal must be connected to the RS422 (-) Data Out Terminal and the RS422 (+) Data In Terminal must be connected to the RS422 (+) Data Out Terminal.
Options Twisted Pair + Host Computer Load 120 ohms Gnd - + Gnd - + In Out 400 Series Instrument - + Gnd - + In Out 400 Series Instrument Figure 2 RS485 Interface 27
28 Options 4.1.3 Communication Protocol The Model 414A has a real time clock and enables the time and date to be set and printed on tickets. The date format can be European (days/months/years) or USA (months/days/years), while the time is on a 24 hour clock. Note that the clock will only retain its time for 3 days minimum if there is no power connected to the instrument. After this period, the clock may need to be reset.
Options 29 A CTS input is provided, and will prevent the instrument from transmitting any further characters to a printer if the printer buffer is full. The CTS input is usually connected to the "Data Buffer Full" output from the printer. If the printer buffer is large enough to handle the messages output from the Batch Controller, then this input need not be used and can be left unconnected.
30 Calibration 5. CALIBRATION The Calibration routine enables the Setup Parameters to be programmed, as well as enabling the input signals to be checked. The calibration routine can be entered in two ways: 1 By connecting a wire link (or switch) to the rear terminal strip across terminals 1 and 2 or, 2 By pressing the STOP key and while still holding, press the DISPLAY key. Both keys must then be held for approximately 6 seconds.
Calibration 31 On first entering the Calibration routine, the display will show: CAL Batch Option Test End Setup Program parameters (see section 5.1). Enter Batch parameters (see section 5.2) Option - if installed (see Section 5.3). Check Input Signals (see section 5.4) Exit to Normal Operation. The user can toggle between these modes using the DISPLAY switch and by using the STOP switch, select the appropriate mode.
32 Calibration 5.1 PROGRAMMING THE SETUP PARAMETERS Step 1 Display CAL BATCH OPTION TEST END Description Select the Calibrate mode to setup program parameters. Select Batch to enter Batch Setup parameters. Option (if installed). Select the test mode to check input signals. Exit to normal operation. Text Ref 5.2 5.3 5.4 The following steps are displayed if CAL is selected. 2 RESTOT Reset all totals to zero. To reset all totals (resettable and accumulated) press the BATCH SET key once.
Calibration Step Display Description 33 Text Ref 9 CUTOFF xx.x The signal Cutoff. Enter as a % of the Span. 10 F dPt Number of decimal points with which the Rate is to be displayed between 0 to 0.00000. 11 t.base The Timebase with which the Span is entered 3.2.1 must be programmed. 60secs hours days secs units/min units/hour units/day units/second FILTER The filter constant for filtering the rate display. 1 to 99 No filtering.
34 Calibration 5.2 ENTERING THE BATCH PARAMETERS Step 1 Display BATCH OPTION TEST END CAL Description Enter Batch Parameters. Option (if installed) Check Input Signals. Exit to normal operation. Program Setup Parameters. Text Ref 5.3 5.4 5.1 The following steps are displayed if BATCH is selected. 2 BATCH L xxxxxx 3 4 5 AUTO S Off On xx:xx START. T xx:xx PREST xxxx Maximum Batch Size which can be entered. Set to 0 if no limit on batch size. Automatic restart feature. Disable. Enable.
Calibration Step 6 7 8 Display COUNT dn up The Batch Total counts Up or Down. Count down from the batch quantity. Count up from zero. T OUT The Signal Timeout in seconds. (Setting to 00 disables this feature.) AOC En Dis 9 Description AUTO R Off On Automatic Overrun Compensation. Note that the Signal Timeout must be greater than 0 (ie enabled) for this feature to work. Enable. Disable. Auto Reset (not displayed if Auto Restart is programmed - Step 3 above).
36 Calibration 5.3 PROGRAMMING OPTIONS Step 1 Display Description OPTIONS Test End CAL Batch Options (if installed). Check the Input Signals. Exit to normal operation. Program Setup Parameters. Set Batch Parameters. Text Ref 5.4 5.1 5.2 If the RS232/422/485 option is installed, the following will be displayed: 2 DF Eur USA Date Format. European (ie. days/months/years). USA (ie. months/days/years). 4.1 3 Date xx:xx:xx Enter date as: Years:Months:Days. 4.
Calibration Step Display Description 8 SIGNAL rs232 rs422 Signal Type. RS232. RS422/RS485. 9 ID NO 0 1 - 99 Unit Identification Number. None. Id number. 10 P TYPE xx Printer/Computer Type. 00 01 02 03 04 05 Standard Computer Printer. EPSON CTM 290 Slip Printer. Model 624 Roll Printer. EPSON TM290-2 Slip Printer. Contrec Model 632-2 Printer. Syntest SP-210 Printer. 20 Computer.
38 Calibration 5.4 CHECKING THE INPUT SIGNAL Step 1 Display Description TEST OPTIONS CAL BATCH END Check the Input Signals. Options (if installed). Program Setup Parameters. Set Batch Parameters. Exit to normal operation. Text Ref 5.3 5.1 5.2 The following steps are displayed if TEST is selected. 2 Sr x.xx Software revision number. Depending on the input selected, the input current or voltage will be displayed. 3 4-20mA xx.xx Displayed for 1 second followed by the actual current. 0-20mA xx.
Input Circuits 39 6. INPUT CIRCUITS 6.1 THE SIGNAL INPUT The basic circuit of the input is shown below. Both the current and voltage signals are fed to a data selector but only one signal is processed, depending upon whether a current (4-20mA or 0-20mA) or a voltage (1-5 V or 0-10 V) input configuration is selected. The signal is fed to a voltage to frequency convertor and transmitted to the microprocessor via an opto-coupler.
40 Input Circuits Model 414 Batch Controller 11 + Transmitter - 4-20mA 8-24 VDC 9 250 ohms 8 Ground 2 Transmitter Powered by the Flow Computer External Loop Power Batch Controller + Transmitter - 4-20mA 9 250 ohms 8 + Chart Recorder - 4-20mA Loop with External Power Supply INPUT CONNECTIONS
Input Circuits 41 6.3 REMOTE SWITCH INPUTS Remote push-buttons can be connected to the Model 414A to duplicate the switches on the front panel.
42 Installation 7. INSTALLATION 7.1 GENERAL The terminal designations for the Model 414A Batch Controller are given on the following pages. The cutout hole in the panel should be 5.5" (139mm) wide x 2.6" (67mm) high. Two side clips are supplied to secure the instruments into panel. A case earthing point is provided via an earth lug on the side of the case. Note that this earthing point is for the case only and there is complete electrical isolation between this point and all electronic circuits.
Installation 43 Overall shields should be connected to the case earth at the instrument end only. This connection should be as short as possible and connected to the earthing lug on the side of the case. In order to comply with the requirements for Electromagnetic Compatibility as per EMC-Directive 89/336/EEC of the Council of European Community, this wiring practice is mandatory.
44 Installation 7.
Trouble Shooting 45 8. TROUBLE SHOOTING Batcher does not reset. The Signal Timeout has been set to an excessively long period and has not timed out at the end of the last batch. Batch will not start or relay 1 will not close. Ensure that the instrument has not timed out as controlled by the Signal Timeout and that a Flow Alarm condition does not prevail. Pressing the Stop switch will cancel this condition. Check for a fault on the flow input before restarting. Batcher stops midway through a batch.
46 Trouble Shooting Counting erratically This can be caused by lack of shielding on the input. Shield the input signal with the shield earthed at the Batch Controller only. Instrument acting erratically Erratic operation can be the result of severe electrical interference. Considerable attention has been given to designing the Batch Controller to withstand electrical interference. However, in extreme cases, loads may be encountered which are exceptionally inductive and may require additional protection.
Trouble Shooting 47 8.1 ERROR CODES The instrument has extensive self test facilities and will display an error code if it detects an invalid condition. If the instrument displays an error code other than those listed below, please contact the factory. Error codes are displayed as "Err 12" and a list of commonly encountered codes are given below: Error Codes Input Errors 11 13 14 Invalid input configuration programmed. Signal less than 3.5mA. Communications Input error (RS232/422/485 Interface).
48 Index Index $ Access, 33 Accumulated Total, 10 Auto Reset, 9 Auto Restart, 16 Automatic Overrun Compensation, 17 % Backlite, 4 Batch Limit, 10 Batch Set, 8 Battery Backup, 7 Baudrate, 28 & Calibration, 30 Check the Input, 38 Communication Protocol, 28 Computer, 29 Conformal Coating, 4 Control Functions, 11 Control Relay, 13 Count Down, 9 Count Up, 9 Cutout, 5 ' Date, 28 DC Input Voltage, 42 Decimal Points, 32 Dimensions, 5 Display Key, 10 Displayed Information, 10 Multipoint Communication, 26 (
Index Slow Start, 13 Slow Stop, 13 Specification, 5 Starting, 9 Stop Key, 13 Stopping, 9 Switching Current, 6 Switching Power, 6 7 Terminal, 44 Ticket, 28 Time Clock, 28 Time Delay, 13 Total Conversion, 22 Transducer Supply, 5 Trouble Shooting, 45 : Wiring Designations, 44 49
