Aalborg TIO Totalizer I,O Flow Monitor,Controller User Manual

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OPERATING MANUAL

TIO

Totalizer-Input/Output

Flow Monitor/Controller

Technical Data Sheet No.: TD-TIO-0911 Rev C Date of Issue: January 2013

Aalborg7is a registered trademark of Aalborg7 Instruments & Controls.

NOTE: Aalborg7 reserves the right to change designs and dimensions at its sole

discretion at any time without notice. For certified dimensions please contact Aalborg7.

TABLE OF CONTENTS

1. UNPACKING THE TIO TOTALIZER......................................................

1.1 Inspecting Package for External Damage..................................................................

1.2 Unpacking the TIO Totalizer.....................................................................................

1.3 Returning Merchandise for Repair.............................................................................

2. SAFETY INSTRUCTIONS / INTRODUCTION...............................................

3. SPECIFICATIONS.............................................................................

4. ELECTRICAL CONNECTIONS................................................................

4.1 Power Supply Connections........................................................................................

4.2 Process Variable (PV) Input Signal Connections..................................................

4.3 Set Point (SP) Output Signal Connections............................................................

4.4 Digital Communication Interface Connections......................................................

4.5 Digital and Pulse Optically-Isolated Output Connections....................................

5. LCD KEY-PAD OPERATION: DATA ENTRY AND CONFIGURATION.....................

5.1 Display Indications....................................................................................................

5.1.1 Set Point Control (only for devices set as controller)..........................................

5.2 Menu Structure....................................................................................................

5.3 Parameter Entry.........................................................................................................

5.3.1 Submenu “Change PP Password”.............................................................................

5.3.2 Submenu “Device Information”...........................................................................

5.3.3 Submenu “Measuring Units”................................................................................

5.3.4 Submenu “User-Defined Units”..................................................................................

5.3.5 Submenu “K-Factors Settings”.............................................................................

5.3.6 Submenu “Alarm Settings”........................................................................................

5.3.7 Submenu “Totalizer #1”............................................................................................

5.3.8 Submenu “Totalizer #2”.......................................................................................

5.3.9 Submenu “Pulse Output”...........................................................................................

5.3.10 Submenu “Opt. Outputs Settings”............................................................................

5.3.11 Submenu “Display Settings”.................................................................................

5.3.12 Submenu “Device Function”......................................................................................

5.3.13 Submenu “Communication Settings”....................................................................

5.3.14 Submenu “Device Calibration”..............................................................................

5.3.15 Submenu “Signal Conditioner”............................................................................

5.3.16 Submenu “Program Set Point”..................................................................................

5.3.17 Submenu “Event Register Menu”.........................................................................

5.3.18 Submenu “Diagnostic Menu” “Event Register Menu”...........................................

6. INSTALLATION............................................................................

6.1 General Directions.....................................................................................................

6.2 Hardware Installation............................................................................................

6.2.1 Connecting TIO to GFM series flow meter............................................................

6.2.2 Connecting TIO to GFC series flow controller...........................................................

6.2.3 Connecting TIO to flow meters / controllers from other manufacturers

(stand alone)............................................................................................................

1 1 1

6 6 7 8 11

13 13 15 17 18 19 21 20 22 25 25 27 29 32 33 34 35 36 37 40 42 43 47

49 49 50 57

7. TROUBLESHOOTING....................................................................

7.1 Common Conditions...........................................................................................

7.2 Troubleshooting Guide........................................................................................

APPENDIX A TIO Totalizer Input/Output Flow Monitor/Controller EEPROM Variables APPENDIX B Internal K-Factors Table APPENDIX C Totalizer-IO ASCII Commands Set APPENDIX D Mechanical Drawings APPENDIX E Circuit Layout Diagrams APPENDIX F Warranty

68 69

71 76 77 92 93 95

1. UNPACKING THE TIO TOTALIZER

1.1 Inspect Package for External Damage

Your TIO Totalizer-Input/Output Flow Monitor/Controller was carefully packed in a sturdy cardboard carton with anti-static cushioning materials to withstand shipping shock. Upon receipt, inspect the package for possible external damage. In case of external damage to the package, contact the shipping company immediately.

1.2 Unpack the TIO Totalizer

Open the carton carefully from the top and inspect for any sign of concealed shipping damage. In addition to contacting the shipping carrier, please forward a copy of any damage report to your distributor or to Aalborg7 directly. When unpacking the instrument make sure that you have all the items indicated on the Packing List. Please promptly report any shortages.

1.3 Returning Merchandise for Repair

Please contact your distributor’s customer service representative, or Aalborg7 if you purchased your TIO instrument directly. Request a Return Authorization

Number (RAN). Equipment returned without an RAN will not be accepted.

Aalborg7 reserves the right to charge the customer a fee for equipment returned under warranty claims if the instruments are tested and found to be free from warrantied defects. Shipping charges are borne by the customer. Instruments returned “collect” will not be accepted! It is mandatory that any equipment

returned for servicing be purged and neutralized of any dangerous contents including but not limited to toxic, bacterially infectious, corrosive or radioactive substances. No work shall be performed on a returned product unless the customer submits a fully executed, signed SAFETY CERTIFICATE. Please request form from the Service Manager.

The TIO Totalizer-Input/Output Flow Monitor/Controller is a microcontroller-driven device designed to linearize the flow meter/controller flow curve and to display instantaneous Flow Rate, Total and Accumulated Total. This product is designed to be used primarily with Aalborg7 series GFM/GFC analog flow meters/controllers but can be also used with any commercial flow meters/controllers with analog 05 (0-10) Vdc or 4-20 mA interface.

The following functions and features are supported:

• Built-in Flow Linearizer (10 point linearization of the flow curve).

• Up to 47 different volumetric and mass flow engineering units (including user-

defined).

• Graphic LCD with large 13mm (0.51") digits for Flow Rate and 5.5mm (0.21")

for Total.

• User-adjustable LCD back light and contrast level.

• Digital RS-232 or RS-485 interface (multidrop capability for up to 64 devices).

• Compact design for unit mount, panel mount, wall mount or field mount

applications.

• Two independent programmable Totalizers.

• User-programmable, optically-isolated pulse output.

• Two programmable optically-isolated digital outputs for different events.

• Low and High Flow Alarms with programmable Action Delay.

• Flow controllers Set Point command control via local LCD or digital interface.

• Programmable Set Point table with ramping up/down capability for up to 16

steps.

• Free Configuration and Monitoring Utility Software.

AALBORG7 warranties and all other responsibilities by direct or implied are voided if users fail to follow all instructions and procedures described in this manual.

LIFE SUPPORT APPLICATIONS: The TIO is not designed for use in life support applications where malfunctioning of the device may cause personal injury. Customers using or selling this device for use in such applications do so at their own risk and agree to be fully responsible for any damages resulting from improper use or sale.

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Some of the IC devices used in the TIO are static-sensitive and may be damaged by improper handling. When adjusting or servicing the device, use of a grounded wrist strap is recommended to prevent inadvertent damage to the integral solid-state circuitry.

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2. SAFETY INSTRUCTIONS / INTRODUCTION

3. SPECIFICATIONS

ADC/DAC RESOLUTION: 12 bit.

ACCURACY: ±0.1% F.S.

ANALOG INPUTS: 0-5 Vdc, 4-20 mA, 5-10 Vdc (jumper-selectable),

0-10 Vdc (special order).

ANALOG OUTPUTS: 0-5 Vdc, 4-20 mA (jumper-selectable), 0-10Vdc

(special order).

LCD: 128x64 graphic LCD with instantaneous Flow reading

and Total volume indication. Adjustable LCD contrast and back light. Refresh rate 10 times/sec.

KEY-PAD: Local 6 tactical push buttons.

DATA PROTECTION: EEPROM backup of all settings, backup Totalizer #1

every one second. Data retention at least 10 years. Password protection for configuration data.

PULSE OUTPUT: User-programmable, optically-isolated, with preset

active low time interval (10 – 6550 ms), UCE ≤ 40Vdc, ICE ≤ 150 mA (Voltage Isolation: 250 Vrms).

DIGITAL OUTPUT: Two programmable, optically-isolated. UCE ≤ 40Vdc,

ICE ≤ 150 mA (Voltage Isolation: 250 Vrms).

DIGITAL INTERFACE: RS-232 or RS-485 (multidrop capability up to 64

devices).

POWER REQUIREMENTS: 12 – 26 Vdc, 100 mV maximum peak-to-peak output

noise (up to 60 mA maximum load).

Protocol: Proprietary ASCII software interface command set. Speed: 1200 - 2400 - 4800 - 9600 -19200 – 38400 – 57600 – 115200

baud (user-selectable). Default 9600 baud.

Configuration: Stop bit: 1

Data bits: 8 Parity: None

Flow Control: None Addressing: Maximum 255 addresses, default

address 11 hex. (for RS-485 option only).

Type: RS232 or RS485 2-wire.

INTERFACE CONNECTORS: Process I/O signals and digital RS-232/RS-485

interface: miniature 9 pin female D-SUB connector. Digital optically-isolated outputs: TERMINAL BLOCK HEADER 4POS 3.5MM male pins, Shrouded (Mated connector: Tyco Electronics P/N: 284510-4).

ENVIRONMENT: Installation Level II; Pollution Degree II.

ELECTROMAGNETIC COMPATIBILITY:

Compliant ref. 89/336/EEC as amended. Emission. Standard: EN 55011:1991, Group 1, Class A. Immunity Standard: EN 55082-1:1992.

OPERATING TEMPERATURE:-10 °C to +70 °C (14 °F to +158 °F).

DIMENSIONS: 86.4 x 76.2 x 19.1 mm (3.4" x 3.0" x 0.75") - W x H x D.

WEIGHT: Approximately 125g / 0.3 lbs.

4. ELECTRICAL CONNECTION

PIN FUNCTION NOTE

Power supply, common Power input

Power supply, positive Power input 12 – 26 Vdc

RS232 RX, Optional RS485 (+)

Communication (RS-232 – input, RS-485 – input/output)

Analog Input (+), PV input Input

Analog Output (+), PV set point Output

RS232 Signal GND (RS-485 GND Optional)

Communication reference

RS232 TX, Optional RS485 (-)

Communication (RS-232 – output, RS-485 – input/output)

Analog Input/Output reference (common for pins 4 and 5)

+5Vdc reference input (for 5-10 Vdc interface only)

Figure 4.1 - TIO 9 PIN "D" CONNECTOR CONFIGURATION

4.2 Process Variable (PV) Input Signal Connections

Depending on the jumper J2 configuration Input signal can be set to 0-5, 5-10, 0-10 Vdc or 4-20 mA.

CAUTION: Do not apply power voltage above 28Vdc.

Doing so will cause device damage or faulty operation.



CAUTION: When connecting the external signals to the input terminals always check actual jumper J2 configuration. Do not exceed the rated

values shown in the specifications (see Table 4.1). Failure to do so

might cause damage to this device. Be sure to check if the wiring and the polarity of the power supply and PV signals are correct before turning the power ON. Wiring error may cause damage or faulty operation.



Make sure power is OFF when connecting or disconnecting any cables or wires in the system.

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The power supply (PS), process variable (PV) input, set point (SP) control output, and digital communication interface signals are connected to the TIO via miniature 9 pin female D-SUB connector.

4.1 Power Supply Connections

The power supply requirements for TIO are: 12 to 26 Vdc, (unipolar power supply).

DC Power (+) --------------- pin 2 of the 9 pin "D" connector DC Power (-) --------------- pin 1 of the 9 pin "D" connector

4.3 Set Point (SP) Output Signal Connections

Set Point (SP) output signal connection is required only if TIO is mated to the flow controller and will be used as a source for a Set Point control signal. Depending on the jumper J2 configuration, SP output signal can be set to 0-5, 0-10 Vdc or 4-20 mA.

Table 4.1 Maximum rated values for PV input signals

INPUT

TYPE

J2 JUMPER

CONFIGURATION

MAXIMUM

SIGNAL

LEVEL

NOTE

J2D J2E J2F

0-5 Vdc 10 -11 14 -15 17-18

≤6 Vdc

5-10 Vdc 11 -12 14 -15 17-18

≤11 Vdc

+5Vdc reference signal must be used (GFM/GFC option)

0-10 Vdc 11 -12 14 -15 17-18

≤11 Vdc

Special Order option! (PCB hardware must be changed)

4-20 mA 10 -11 13 -14 16-17

≤25 mA

(249 Ohm passive, not isolated current input)

Figure 4.2 - TIO Input/Output Configuration Jumpers

PV input (+) --------------- pin 4 of the 9 pin “D” connector. PV input (-) --------------- pin 8 of the 9 pin “D” connector.

Table 4.2 Maximum rated load impedance for SP output signals

OUTPUT

TYPE

J2 JUMPER

CONFIGURATION

MAXIMUM

LOAD

IMPEDANCE

NOTE

J2A J2B J2C

0 - 5 Vdc 2 - 3 5 - 6 8 - 9

≤1000 Ohm

0 - 10 Vdc 2 - 3 5 - 6 8 - 9

≤5000 Ohm

Special Order option! (PCB hardware must be changed).

4 – 20 mA 1 - 2 4 - 5 7 - 8

≤900 Ohm

(24 Vdc PS)

Self-powered (non-isolated) current loop. For 12 Vdc PS the load impedance should not exceed 400 Ohm.

CAUTION: When connecting the load to the output terminals always check actual jumper J2 configuration. Do not exceed the rated values shown in the specifications (see Table 4.2). Failure to do so might cause damage to this device. Be sure to check if the wiring and the polarity of the power supply and SP signals are correct before turning the power ON. Wiring error may cause damage or faulty operation. Do not connect external voltage source to the SP output terminals.

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PV output (+) --------------- pin 5 of the 9 pin "D" connector PV output (-) --------------- pin 8 of the 9 pin "D" connector

WARNING: The 4-20 mA current loop output is self-powered (nonisolated). Do not connect an external voltage source to the output signals.

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4.4 Digital Communication Interface Connections

The digital interface operates via RS-232 (optional RS-485) and provides access to all applicable internal configuration parameters and data.

Communication Settings for RS-232/RS-485 communication interface:

Baud rate: default 9600 baud (user-selectable. See specification section).

Stop bit: .................... 1

Data bits: .................... 8

Parity: .................... None

Flow Control: .................... None

RS-232 Communication Interface Connection:

Crossover connection must be established:

RS-232 RX (pin 2 on the host PC DB9 connector)------pin 7 of the 9 pin "D" connector (TX-)

RS-232 TX (pin 3 on the host PC DB9 connector)------pin 3 of the 9 pin "D" connector (RX+)

RS-232 SIGNAL GND (pin 5 on the host PC DB9 connector)------pin 6 of the 9 pin "D" connector

RS-485 Communication Interface Connection:

The RS485 converter/adapter must be configured for: multidrop, 2 wire, half duplex mode (See Figure 4.3). The transmitter circuit must be enabled by TD or RTS (depending on which is available on the converter/adapter). Settings for the receiver circuit should follow the selection made for the transmitter circuit in order to eliminate echo.

RS-485 T(-) or R(-) ----------------- pin 7 of the 9 pin "D" connector (TX-) RS-485 T(+) or R(+) ----------------- pin 3 of the 9 pin "D" connector (RX+) RS-485 GND (if available) ----------------- pin 6 of the 9 pin "D" connector

Figure 4.3 RS-485 Multidrop Half Duplex Two Wire System

When the TIO device is set as the last device on the RS-485 bus segment and 220 Ohm bus termination is required, set the jumper J2G to position 19-20. This will result in connection 220 Ohm resistor between RS-485 (+) and (-) terminals.

4.5 Digital and Pulse Optically-Isolated Outputs

Connections

TIO is equipped with two programmable digital optically-isolated outputs. Each output can be assigned to any one of many different system events or configured as a pulse output (see Paragraph 5.3.9).

Digital optically-isolated outputs use dedicated 4 position 3.5mm male terminal block header J1 located on the top side of the TIO enclosure (see Figure 6.1). (Mated interface connector: Tyco Electronics P/N: 284510-4).

Optocoupler #1 - Terminal J1 (pins 1 and 2):

Plus (+) (passive) --------------- Terminal J1 pin 1 Minus (-) (passive) --------------- Terminal J1 pin 2

Optocoupler #2 - Terminal J1 (pins 3 and 4):

Plus (+) (passive) --------------- Terminal J1 pin 3 Minus (-) (passive) --------------- Terminal J1 pin 4

WARNING: Optically-isolated outputs require application of external DC voltage across terminals. Do not exceed maximum allowed limits for voltage and current provided below:

2 V < UCE < 40 V

0.2 mA < ICE < 150 mA

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WARNING: Optically-isolated outputs have maximum absolute voltage rating 250 Vdc RMS. Do not exceed maximum allowed limits for voltage. Doing so may cause personal injury or damage to this device.

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5. LCD KEY-PAD OPERATION: DATA ENTRY AND

CONFIGURATION

5.1 Display Indications

Initially, after the power is first turned on, the Banner Screen is shown for 2 seconds, then device firmware and EEPROM data base table revisions on the first line, communication interface type on the second line, baud rate and RS-485 hexadecimal address value on third and fourth lines are shown for another 2 seconds. Subsequently, the actual process information (PI) is displayed.

Figure 5.1: TIO Firmware and Communication Interface Info Screen

Based on device configuration (Device Function as flow meter or flow controller), different parameters may be displayed in the Process Information (PI) screen by pressing the UP or DN pushbuttons.

Process Information screens can be configured to be static or dynamic (see Paragraph 5.3.11 “Display Menu”). Using Screen Mask settings user can enable (unmask) or disable (mask) up to 4 different process information combinations (see Figure 5.4). In the Static Mode the UP button pages through the PI screens in the forward direction, the DN button pages through the PI screens in the reverse direction. When the last PI screen is reached, the firmware “wraps around” and scrolls to the initial PI screen once again.

In the Dynamic Display Mode, firmware initiates automatic screen sequencing with user- adjustable screen Cycle Time (see Paragraph 5.3.11 “Display Menu”). When the last PI screen is reached, the firmware “wraps around” and scrolls to the initial PI screen once again.

Fw: A002 Tbl: A001

Interface: RS-232

Baud Rate: 9600

RS485 address: 11

NOTE: Actual content of the LCD screen may vary depending on the model and device configuration.

99.97

A:D litr/min

T1: 1589324.5 litr

99.97

S: 100.0 litr/min

T1: 1589324.5 litr

Figure 5.2: TIO Initial PI Screen (Device Function: Flow Meter)

Figure 5.3: TIO Initial PI Screen (Device Function: Flow Controller

Device Function: Flow Controller

Figure 5.4: TIO PI Screen (based on device function)

Device Function: Flow Meter

5.1.1 Set Point Control

(only for devices set as controller)

When TIO is configured as controller it can be used to control set point value for mated flow controller using analog output interface.

NOTE: Your TIO device input / output jumpers were factory configured according to your order. Make sure the mated flow controller has an analog input interface compatible with the TIO analog output configuration. Before applying the power and process signals make sure the input /output jumpers are installed in the correct position (See Table 6.5).

51.01

S: 51.0 litr/min

T1: 254898.0

litr

51.01

KF:D litr/min

T2: 436.5

51.01 litr/min

A:D KF:D

T1: 254898.0 litr

T2: 436.5

51.01 litr/min

S 51.0 0.0s

CS: 1 0.0 0

M:D L:O S: Off

litr

51.01

A:D litr/min

T1: 254898.0

51.01

KF:D litr/min

T2: 436.5

51.01 litr/min

A:D KF:D

T1: 254898.0 litr

T2: 436.5

51.01 litr/min A:D KF:D

Events Reg: No Events

PO:E U/P: 1.000 litr DO# 1: Pulse Output DO# 2: Disabled

litr

The Set Point value can be adjusted locally using LCD/keypad, remotely via RS232/RS-485 digital interface or can be programmed in advance using user-preset programs of up to sixteen steps (Program Set Point Mode).

a) Adjusting Set Point value using local LCD/keypad

Current Set Point value is displayed on the second line of the main PI screen, next to the ‘S’ character.

Pressing the ENT button while in the main PI screen will activate Set Point adjustment mode. The first character of the Set Point value will start to flash. Use UP or DN button to increment / decrement digit value from 0-9. Use RIGHT or LEFT button to move cursor to another digit position. When desired Set Point value is entered use the ENT button to accept (save in the EEPROM) new Set Point value.

If at the end of the Set Point value entry the ESC button is pressed instead ENT, the original Set Point value will be restored and Set Point adjustment mode will be deactivated. To exit from the Set Point adjustment mode before Set Point value is accepted, press the ESC button.

b) Controlling Set Point value using Program Set Point mode

To activate Program Set Point mode the following must to be done:

1. Program Set Point mode must be Enabled (see paragraph 5.3.16 a).

2. Program Loop parameter must be set to desired value (On/Off).

3. Program Run parameter must be set to “On” (default settings is Off).

NOTE: Since the Set Point value entered via local LCD/keypad is stored in the non-volatile memory (EEPROM), it will be executed on the next device power up event.

NOTE: If the Program Set Point mode is enabled and the program is running, the Set Point value can be changed at any moment by the execution of the next active step. The Set Point entered via local LCD/keypad can be also changed via digital RS-232/RS-485 interface.

99.97

S: 100.0 litr/min

T1: 1589324.5 litr

NOTE: Before executing, the program should be entered in the program table (see Paragraph 5.3.16)

NOTE: While Program Set Point mode is running, the current Set Point value also can be changed from local LCD/keypad and digital RS-232/RS-485 communication interface. In this case, new Set Point value will be kept only until the next successive program step is executed.

As shown in the above drawing the Program Run parameter can be toggled “On” or “Off” by pressing the RIGHT and LEFT keypad buttons, while PI screen #4 is active. If Program Run status parameter is set to “Off”, the program execution will pause and current SP value will freeze until Program Run status parameter is set to “On”.

5.2 Menu Structure

The diagram on the Figure 5.7 gives a general overview of the standard top-level display menu structure when running firmware version A001. The ESC pushbutton is used to toggle between the Process Mode (PI screens) and the Setup menus.

UP and DN buttons must be used to move through the menu items. When the last item in the menu is reached, the menu “wraps around” and scrolls back to the beginning of the menu items list. Similarly, when the first menu item is highlighted and the UP button is pressed, the menu “wraps around” and scrolls down to the end of the menu item’s list.

All process configuration parameter’s settings are password-protected. In order to access or change them, Program Protection should be disabled. Each time the device is powered up, the Program Protection is enabled automatically. By default, the device is shipped from the factory with the Program Protection (PP) password set to Zero (PP Disabled). If PP password is set to Zero (Disabled), entering a PP password is not required. A subsequent screen will appear and the Program Protection menu item will be selected:

Current flow rate value

51.01 litr/min

Current SP value

Current program step

Program Mode: E/D

Program Loop Mode: On/Off

Program Run Status: On/Off

S 51.0 0.0s

CS: 1 0.0 0

M:D L:Off S: Off

Current step time

elapsed

Figure 5.5

Pressing the UP or DN button to select the Disabled option and then the ENT but- ton to save settings will disable program protection.

If PP password is set to any value more than Zero, the firmware will prompt with “Enter PP Password” (see Figure 5.6). User must enter up to 3 digits program protection code, in order to be able to access password protected menus. Once the correct password is entered, Program Protection is turned off until the unit is powered up again.

Figure 5.6

5.3 Parameter Entry

There are two methods of data entry: • Direct numerical number entry.

• Tabular Input from a table menu.

If the menu with direct numerical entry is selected use the UP or DN button to increment / decrement digit value from 0-9. Use the RIGHT or LEFT button to move the cursor to another digit position. When the desired value is entered, use ENT button to accept (save in the EEPROM) the new value.

If the menu with tabular entry is selected, the available menu options can be set with the UP and DN buttons and are accepted by pressing the ENT button.

5.3.1 Submenu “Change PP Password”

In order to get access to “Change PP Password” menu, Program Protection must be disabled. If PP password is set to Zero (Disabled), entering PP Password is not required and PP can be disabled from “Program Protection” menu (see Figure

5.5). If PP Password is set to any value more than Zero, the firmware will prompt with “Enter PP Password” (see Figure 5.6). User must enter program protection code (up to 3 digits). If PP password is lost or forgotten, contact the factory or your distributor.

NOTE: During data entry the input vales are checked for acceptability. If data is not acceptable, it is rejected and a message is generated indicating that the new data has not been accepted.

Program Protaction (PP)

Change PP Password

Device Information

EngUnits & K-Factor

Totalizer Settings

Opt Output Settings

General Settings

Device Diagnostic

Alarm Settings

***** Main Menu *****

Up/Dn

Event Register Menu

Analog Input counts

Analog Output Value

LCD Back Light Set.

Pulse Output Queue

CPU Temperature

Device Diagnostic

Opt Output #1 Set

Opt Output #2 Set

Totalizer #1

Totalizer #2

Pulse Output

Flow Alarm Mode

Low Flow Alarm

High Flow Alarm

Flow Alarm Delay

Flow Alarm Latch

Measuring Units

UserDefined Units

K-Factor Settings

Device ID & FS Flow

Analog/Com Interface

Firmware/EE Version

Alarm Settings

Totalizer#1 Settings

Totalizer#2 Settings

Pulse & Dig. Outputs

Mated Device Info

General Settings

Display Mode

Screen Cycle Time

Screen Mask

Display Back Light

Display Contrast

Flow Meter

Flow Controller

Baud Rate Settings

RS-485 Bus Address

Full Scale Range

Low Flow Cut-off

Flow PowerUp Delay

Fluid Std. Density

Analog Output Cal.

Analog Input Cal.

Pilot Cal. Timer

Signal Condit. Mode

NRF Num. of Samples

NRF Time Interval

Aver.Filter Damping

FlowLinearizer Mode

Program SP Mode

PSP Loop Mode

PSP Steps Mask

PSP Steps Settings

Totalizer #1 Mode

Tot#1 Flow Start

Tot#1 Action Vol.

Tot#1 PowerOn Delay

Tot#1 Auto Reset

Tot#1 AutoRes Delay

Reset Totalizer #1

Totalizer #2 Mode

Tot#2 Configuration

Tot#2 Flow Start

Tot#2 Action Vol.

Tot#2 PowerOn Delay

Tot#2 Auto Reload

Tot#2 AutoRel Delay

Reset Totalizer #2

PulseOutput Mode

Pulse Flow Start

[Unit]/Pulse

Pulse Active Time

Disabled

Low F. Alarm

High F. Alarm

F. Range H-L

Total#1 Event

Total#2 Event

Pulse Output

Diagnostic

Manual On

UD Unit K-Factor

UD Unit Time Base

UD Unit Use Density

K-Factor Mode

Int. K -Factor Index

User Def'd K-Factor

%FS

ml/sec

ml/min

ml/hr

ml/day

litr/sec

litr/min

litr/hr

litr/day

m^3/sec

m^3/min

m^3/hr

m^3/day

f^3/sec

f^3/min

f^3/hr

f^3/day

gal/sec

gal/min

gal/hr

gal/day

gram/sec

gram/min

gram/hr

gram/day

kg/sec

kg/min

kg/hr

kg/day

lb/sec

lb/min

lb/hr

lb/day

Mton/min

Mton/hr

Igal/sec

Igal/min

Igal/hr

Igal/day

MilL/min

MilL/hr

MilL/day

bbl/sec

bbl/min

bbl/hr

bbl/day

User

Ent

Event Reg. Status

Event Latch Mask

Event Reg. Mask

Reset Event Reg.

Display Settings

Device Function

Communication Sett.

Device Calibration

Signal Conditioner

Program Set Point

Ent

Figure 5.7

TIO Upper Levels

Menu Structure

Once “Change PP Password” menu is selected, the following screen will appear:

In order to protect device configuration parameters when changing the PP password, the old PP password must be entered.

Once old and new passwords are entered the firmware will prompt with a confirmation message (see Figure 5.9) that the new password has been saved.

5.3.2 Submenu “Device Information”

This submenu contains information about the device’s main configuration parameters. These items are informational only, not password-protected, and can’t be changed (read only).

Figure 5.8

Figure 5.9

NOTE: By default the device is shipped from the factory with Program Protection (PP) password set to Zero (PP Disabled).

Figure 5.10

5.3.3 Submenu “Measuring Units”

Use the “Engineering Units and K-Factor Menu” to navigate to “Measuring Units” menu option. This option allows configuration of the flow meter/controller with the desired units of measurement. These are global settings and determine what appears on all process information screens and data log records. Units should be selected to meet your particular metering needs. A total of 47 different volumetric and mass-based engineering units are supported (See Table 5.1).

NOTE: Program the Measuring Units first because subsequent menus may be based on the units selected. Once Flow Unit of Measure is changed the Totalizer’s Volume based Unit of Measure will be automatically changed.

5.3.4 “Submenu User-Defined Units”

In addition to conventional flow units user-defined flow engineering units may be selected. Use the “Engineering Units and K-Factor Menu” to navigate to the “User-defined Units” menu option. This option enables user-defined configuration of any engineering unit required for process measurement.

The following three parameters are available for this function:

a) UD Unit volume K-Factor (defined in Liters), b) UD Unit time base (defined in Seconds), c) UD Unit use density (units with or without density support).

Before using the User-defined Unit, be sure the proper conversion factor of the new unit with respect to one liter is set (the default entry is 1.00 Liter). Also, proper time base values for User-Defined Units must be set.

TABLE 5.1 SUPPORTED ENGINEERING UNITS LIST

NUMBER

FLOW RATE

ENGINEERING

UNITS

TOTALIZER

ENGINEERING

UNITS

DESCRIPTION

1 %FS %s Percent of full scale

2 ml/sec ml Milliliter per second

3 ml/min ml Milliliter per minute

4 ml/hr ml Milliliter per hour

5 ml/day ml Milliliter per day

6 litr/sec litr Liter per second

7 litr/ min litr Liter per minute

8 litr/hr litr Liter per hour

9 litr/day litr Liter per day

10 m^3/sec m^3 Cubic meter per second

11 m^3/ min m^3 Cubic meter per minute

12 m^3/hr m^3 Cubic meter per hour

13 m^3/day m^3 Cubic meter per day

14 f^3/sec f^3 Cubic feet per second

15 f^3/min f^3 Cubic feet per minute

16 f^3/hr f^3 Cubic feet per hour

17 f^3/day f^3 Cubic feet per day

18 gal/sec gal Gal per second

19 gal/min gal Gal per minute

20 gal/hr gal Gal per hour

21 gal/day gal Gal per day

22 gram/sec gram Grams per second

23 gram/min gram Grams per minute

24 gram/hr gram Grams per hour

25 gram/day gram Grams per day

26 kg/sec kg Kilograms per second

27 kg/min kg Kilograms per minute

The following selections are available: 1 second, 60 seconds (1 minute), 3600 seconds (1 Hour), 86400 seconds (1 Day). The default entry is 60 seconds. If a massbased User-defined Unit is desired, the “UD Unit Use Density” parameter must be set to “YES”. The default entry is “NO” so the Fluid STD Density parameter is not used for flow rate calculation.

NUMBER

FLOW RATE

ENGINEERING

UNITS

TOTALIZER

ENGINEERING

UNITS

DESCRIPTION

28 kg/hr kg Kilograms per hour

29 kg/day kg Kilograms per day

30 lb/sec lb Pounds per second

31 lb/min lb Pounds per minute

32 lb/hr lb Pounds per hour

33 lb/day lb Pounds per day

34 Mton/min Mton Metric Ton per minute

35 Mton/hr Mton Metric Ton per hour

36 Igal/sec Igal Imperial Gal per second

37 Igal/min Igal Imperial Gal per minute

38 Igal/hr Igal Imperial Gal per hour

39 Igal/day Igal Imperial Gal per day

40 MilL/min MilL Million Litr per minute

41 MilL/hr MilL Million Litr per hour

42 MilL/day MilL Million Litr per day

43 bbl/sec bbl Barrel per second

44 bbl /min bbl Barrel per minute

45 bbl /hr bbl Barrel per hour

46 bbl /day bbl Barrel per day

47 User User User-defined

5.3.5 Submenu “K-Factors Settings”

Conversion factors relative to Nitrogen are convenient to use when the flow meter/controller mated to the TIO is calibrated for Nitrogen and another gas is required to be measured/controlled.

Conversion factors relative to Nitrogen for up to 22 common gases are stored in the TIO (see APPENDIX II). In addition, provision is made for a user-defined con- version factor. Conversion factors may be applied to all units of measure (except %FS unit) via LCD/Keypad or digital communication interface.

The following three parameters are available for this function:

a) K-Factor Mode: Disable, Internal Index, user-defined (default Disabled) b) Internal K Factor Index: 1 – 22 (from internal K-Factor table, see APPENDIX II) c) User-defined K-Factor: 0.001 – 999.9 (default value is 1.000).

5.3.6 Submenu “Alarm Settings”

TIO provides the user with a flexible Alarm/warning system that monitors the Fluid Flow for conditions that fall outside configurable limits as well as visual feedback for the user via the LCD or via an optically-isolated output. The Flow Alarm has several attributes which may be configured by the user via LCD/Keypad or digital communication interface. These attributes control the conditions which cause the Alarm to occur and to specify actions to be taken when the flow rate is outside the specified conditions.

Depending on the TIO function configuration (flow meter or controller) there are two Alarm algorithms. If the TIO is configured as a flow meter, Flow Alarm conditions become true when the current flow reading is equal to or Higher/Lower than corresponding values of High and Low Flow Alarm levels. If TIO is configured as flow controller, Flow Alarm conditions become true when difference between Set Point value and current flow reading is equal or Higher/Lower than corresponding values of High and Low Flow Alarm levels.

Alarm action can be assigned with preset Delay Interval (0-3600 seconds) to activate the optically-isolated output (separate for High and Low Alarm). Latch Mode control feature allows each optical output to be latched on or follow the corresponding Alarm status.

Following settings are available for Flow Alarm (see Figure 5.7):

Note: The conversion factors will not be applied for the % F.S. engineering unit.

a) Flow Alarm Mode (Tabular entry)

This function determines whether the Flow Alarm is Enabled or Disabled. The following selections are available: Enabled or Disabled. The default entry is Disabled. Alarm Mode selections can be set with the UP and DN buttons and are accepted by pressing ENT button.

b) Low Flow Alarm (Numerical entry)

The limit of required Low Flow Alarm value can be entered in increments of 0.1% from 0 - 100%F.S.

If a Low Alarm occurs, and one of the two optical outputs is assigned to the Low Flow Alarm Event (see paragraph 5.3.10) the optically-isolated output will be activated:

• For Flow Meter function: when the flow is less than the Low Flow Alarm value.

• For Flow Controller function: when the absolute difference between Set Point value and actual flow reading is equal to or higher than the Low Flow Alarm value and Actual Flow value is less than Set Point value.

The Low Flow Alarm condition is also indicated on the corresponding Process Information Screen by displaying L character.

c) High Flow Alarm (Numerical entry)

The limit of required High Flow Alarm value can be entered in increments of 0.1% from 0 - 100% F.S. If a High Alarm occurs, and one of the two optical outputs is assigned to the High Flow Alarm Event (see paragraph

5.3.10) the optically-isolated output will be activated for:

• Flow Meter function: when the flow is more than the High Flow Alarm value.

• Flow Controller function: when absolute difference between Set Point value and Actual Flow reading is equal to or higher than the High Flow Alarm value and actual flow value is more than set point value.

The High Flow Alarm condition is also indicated on the corresponding Process Information Screen by displaying the H character.

NOTE: For Flow Meter function the value of the Low Flow Alarm must be less than the value of the High Flow Alarm.

d) Flow Alarm Action Delay (Numerical entry)

The Flow Alarm Action Delay is a time in seconds that the Flow Rate value remains above the High limit or below the Low limit before an Alarm condition is validated. Valid settings are in the range of 0 to 3600 seconds (default value is 0, no delay).

e) Flow Alarm Action Latch (Tabular entry)

The Flow Alarm Action Latch settings control the Latch feature. If optically-isolated output is assigned to the Flow Alarm Event, in some cases, the Flow Alarm Latch feature may be desirable.

The following settings are available: Disable or Enabled. By default, the Flow Alarm is non-latching. That means the Alarm is indicated only while the monitored Flow Value exceeds the specified set conditions.

5.3.7 Submenu “Totalizer #1”

TIO provides the user with two independent Programmable Flow Totalizers. The total volume of the flowing fluid is calculated by integrating the actual instantaneous fluid flow rate with respect to time. Totalizer #1 (main Totalizer) value is stored in the EEPROM and saved every 1 second. In case of power interruption the last saved Totalizer value will be loaded on the next power on cycle, so the main Totalizer reading will not be lost. Use the “Totalizer Menu” to navigate to the “Totalizer #1” menu option.The following settings are available for Totalizer #1 (see Figure 5.7):

a) Totalizer #1 Mode (Tabular entry)

This option determines whether Totalizer #1 is Enabled or Disabled. The following selections are available: Enabled or Disabled. The default entry is Disabled. Totalizer #1 Mode selections can be set with the UP and DN buttons and are accepted by pressing the ENT button.

NOTE: For Flow Meter function the value of the High Flow Alarm must be more than the value of the Low Flow Alarm.

NOTE: Before enabling the Totalizer, ensure that all Totalizer settings are configured properly. Totalizer Start values must be entered in the currently active Volumetric or Mass flow engineering unit. The Totalizer will not totalize until the Process Flow Rate becomes equal to or more than the Totalizer Start value. Totalizer Event values must be entered in currently active volume or mass based engineering units. If the Totalizer Event at preset total volume feature is not required, set Totalizer Event value to zero (default settings).

b) Totalizer #1 Flow Start (Numerical entry)

This option allows the start of the Totalizer at a preset flow rate. Totalizer #1 will not totalize until the process flow rate becomes equal to or more than the Totalizer #1 Flow Start value. The limit of required Totalizer #1 Flow Start value can be entered in increments of 0.1% from 0 - 100%F.S.

c) Totalizer #1 Action Volume (Numerical entry)

This option allows the user to activate preset required action when the Totalizer reaches a preset volume. Totalizer #1 Action Volume value must be entered in currently active volume / mass-based engineering units. Totalizer #1 Action Event becomes true when Totalizer #1 reading is more or equal to preset "Totalizer #1 Action Volume”. If the Totalizer#1 Action at preset total volume feature is not required, set “Totalizer #1 Action Volume” value to zero (default settings).

d) Totalizer #1 Power On Delay (Numerical entry)

Sometimes it is convenient to start the Totalizer only after specified power-up delay interval. Most of the mass flow meters and controllers require some warm-up time from the power-up event in order to stabilize the process variable output and get an accurate reading. “Totalizer #1 Power On Delay” option allows set specified a time interval which must elapse from the device power-up event before the Totalizer will be activated. Valid settings are in the range of 0 to 3600 seconds (default value is 0, no delay).

e) Totalizer #1 Auto Reset (Tabular entry)

This option allows automatic reset of the Totalizer #1 when it reaches preset Action Volume value. This feature may be convenient for batch processing when predefined volume of the fluid must be repeatedly dispensed into the process. The following selections are available: Enabled or Disabled.

The default entry is Disabled. Totalizer #1 Auto Reset selections can be set with the UP and DN buttons and are accepted by pressing the ENT button.

f) Totalizer #1 Auto Reset Delay (Numerical entry)

This option may be desirable when the “Totalizer #1 Auto Reset” feature is enabled. Valid settings are in the range of 0 to 3600 seconds (default value is 0, no delay).

g) Reset Totalizer #1 (Numerical entry)

The Totalizers #1 reading can be reset by selecting the “Reset Totalizer #1” menu option. A typical display with Totalizer #1 Reset screen is shown below.

Once the “YES” option is selected, Totalizer #1 will be reset and the following conformation screen will appear:

5.3.8 Submenu “Totalizer #2”

The Totalizer #2 (pilot Totalizer) value is stored in the flow meter volatile memory (SRAM) and saved every 100 ms. In case of power interruption the Totalizer #2 volume will be lost (reset to zero). It is preferable to use Totalizer #2 for short term process flow calculation (for example: batch processing) Use the “Totalizer Menu” to navigate to “Totalizer #2” menu option. The following settings are available for Totalizer #2 (see Figure 5.7):

a) Totalizer #2 Mode (Tabular entry)

This option determines whether Totalizer #2 is Enabled or Disabled. The following selections are available: Enabled or Disabled. The default entry is Disabled. Totalizer #2 Mode selections can be set with the UP and DN buttons and are accepted by pressing the ENT button.

Reset Totalizer #1:

YES

DO YOU WANT

RESET TOTALIZER?

*******************

Totalizer Has

been reset!

Press any Key...

NOTE: Before enabling the Totalizer, ensure that all Totalizer settings are configured properly. Totalizer Start values must be entered in currently active Volumetric or Mass Flow engineering units. The Totalizer will not totalize until the process flow rate becomes equal to or more than the Totalizer Start value. Totalizer Event values must be entered in currently active volume or mass-based engineering units. If the Totalizer Event at preset total volume feature is not required, then set the Totalizer Event value to zero (default settings).

b) Totalizer #2 Configuration (Tabular entry)

Totalizer #2 can be configured to count up or down. When configured to count down, be sure “Totalizer #2 Action Volume” parameter is set to the desired value of more than zero. In this case Totalizer #2 Action Event will be activated when the Totalizer counts down to zero. The following selections are available: Count UP or Count DN. The default entry is Count UP. Totalizer #2 configuration selections can be set with the UP and DN buttons and are accepted by pressing ENT button.

c) Totalizer #2 Flow Start (Numerical entry)

This option allows the start of the Totalizer at a preset flow rate. Totalizer #2 will not totalize until the process flow rate becomes equal to or more than the Totalizer #2 Flow Start value. The limit of required Totalizer #2 Flow Start value can be entered in increments of 0.1% from 0 -100%F.S.

d) Totalizer #2 Action Volume (Numerical entry)

This option allows the user to activate the preset required action when:

• The totalizer reaches a preset volume if the totalizer is configured to count up. (or)

• The totalizer reaches zero value if the totalizer is configured to count down.

Totalizer #2 Action Volume value must be entered in currently active volume / mass-based engineering units. When set to count up, Totalizer #2 Action Event becomes true when Totalizer #2 reading is more or equal to preset “Totalizer #2 Action Volume”. If the Totalizer#2 Action at preset total volume feature is not required, set “Totalizer #2 Action Volume” value to zero (default settings).

NOTE: When Totalizer #2 is configured to count down, be sure “Totalizer #2 Action Volume” value is set to any value higher than zero.

e) Totalizer #2 Power On Delay (Numerical entry)

Sometimes it is convenient to start the Totalizer only after a specified power-up delay interval. Most of the mass flow meters and controllers require some warm-up time from the power-up event in order to stabilize process variable output and to get accurate reading. “Totalizer #2 Power On Delay” option allows setting a specified time interval which must elapse from the device power-up event before the Totalizer will be activated. Valid settings are in the range of 0 to 3600 seconds (default value is 0, no delay).

f) Totalizer #2 Auto Reload (Tabular entry)

This option allows automatic reset/reload Totalizer #2 when it reaches preset Action Volume value (when configured to count UP) or zero value (when configured to count Down). This feature may be convenient for batch processing when predefined volume of the fluid must be repeatedly dispensed into the process. The following selections are available: Enabled or Disabled. The default entry is Disabled. Totalizer #2 Auto Reload selections can be set with the UP and DN buttons and are accepted by pressing the ENT button.

g) Totalizer #2 Auto Reset Delay (Numerical entry)

This option may be desirable when “Totalizer #2 Auto Reload” feature is enabled. Valid settings are in the range of 0 to 3600 seconds (default value is 0, no delay).

h) Reset Totalizer #2 (Numerical entry)

Totalizers #2 reading can be reset by selecting “Reset Totalizer #2” menu option. A typical display with Totalizer #2 Reset screen is shown below.

Once the “YES” option is selected, Totalizer #2 will be reset and the following conformation screen will appear.

Reset Totalizer #2:

YES

DO YOU WANT

RESET TOTALIZER?

*******************

Totalizer Has

been reset!

Press any Key...

5.3.9 Submenu “Pulse Output”

The flow Pulse Output is operates independently from Totalizers and is based on configuration settings (see Figure 5.7) which can provide pulse frequency proportional to instantaneous fluid flow rate.

The LCD/keypad and digital communication interface commands are provided to:

• Enable/Disable Pulse Output

• Start Pulse Output at preset flow rate (0.0 – 100.0 %F.S.)

• Configure the Unit/Pulse value (in current engineering units)

• Configure Pulse Active On Time (10 - 6553 ms)

For example: Maximum flow rate = 1200 kg/min

(1200 kg/min = 20 kg/sec) If unit per pulse is set to 1200 kg per pulse, the Optical Pulse Output will pulse once every minute.

If unit per pulse is set to 20 kg per pulse, the Optical Pulse Output will pulse once every second.

The Optically-isolated Pulse Output incorporates Pulse output queue, which accumulates pulses if the Pulse Output is accumulating process flow faster than the pulse output hardware can function. The queue will allow the pulses to “catch up” later if the flow rate decreases. A better practice is to slow down the Pulse Output by increasing the value in the Unit/Pulse setting in the Pulse Output menu (see Figure 5.7).

NOTE: The Pulse Output minimum Active On time is a 10 milliseconds (.01 second). The Optical Pulse Output cannot operate faster than one pulse every 100 millisecond (.1 second). A good rule to follow is to set the Unit/Pulse value equal to the maximum flow in the same units per second. This will limit the pulse rate to no faster than one pulse every second.

NOTE: If Pulse Output feature is required, one of the Digital OpticallyIsolated outputs must be assigned to the “Pulse Output” function (see Paragraph 4.3.10). Pulse output signal will be accessible via corresponding Digital Optically-Isolated output on the screw terminal header J1 (see Paragraph 3.5 for proper wiring connections).

5.3.10 Submenu “Opt. Outputs Settings”

Two sets of optically-isolated digital outputs are provided to actuate user-supplied equipment. These are programmable via digital interface or LCD/Keypad such that the outputs can be made to switch when a specified event occurs (e.g. when a Low or High Flow Alarm limit is exceeded, when the Totalizer reaches a specified value), or it may be directly controlled by user.

The user can configure each optical output action from 9 different options:

• Disabled: No Action.

(Output is not assigned to any events and is not energized).

• Low Flow Alarm.

• High Flow Alarm.

• Range between H&L Flow Alarm settings.

• Totalizer #1 reading exceed set limit.

• Totalizer #2 reading exceed set limit.

• Pulse Output function.

• Diagnostic: Output will be energized when any of the Diagnostic or

System events are active.

• Manual On Control: Output will be energized until Disabled option is

selected.

By default both optically-isolated outputs are disabled.

NOTE: Optically-isolated outputs are accessible via screw terminal header J1 and require application of external DC voltage across terminals. See Paragraph 4.5 for proper wiring connections.

5.3.11 Submenu “Display Settings”

Process Information screens can be configured to be static (manual control) or dynamic (automatic sequencing). In the static mode pressing the UP button allows the user to page through the PI screens in the forward direction. Pressing DN button, pages through the PI screens in the reverse direction. When the last PI screen is reached, the firmware “wraps around” and scrolls to the initial PI screen once again.

Use the “General Settings” menu to navigate to the “Display Settings” menu option (See Figure 5.7).

The following settings are available for LCD Display:

a) Display Mode (Tabular entry)

This option determines whether Display screens are in Static (manual control) or Dynamic (automatic sequencing) mode. The following selections are available: Static or Dynamic. The default entry is: Static (manual control). Display screens mode parameter can be set with the

UP and DN buttons and are accepted by pressing the ENT button.

b) Screen Cycle Time (Numerical entry)

This menu selection defines the time interval in seconds for each PI screen to be displayed in the dynamic mode (automatic sequencing). Screen Cycle Time can be set to any value in the range between 1 to 3600 seconds (numerical entry).

c) Screen Mask (Tabular entry)

Using Screen Mask settings the user can enable (unmask) or disable (mask) up to 4 different process variable combinations (see Figure 5.4). By default the unit is shipped from the factory with all PI screens enabled. A typical display with Screen Mask selection is shown below.

NOTE: PI screens which are masked in the Screen Mask Register (see below) will be skipped.

Screen Masc:

Screen #2 [*] Screen #3 [*] Screen #4 [*]

Screen #1 [*]

In the example shown above, all PI screens are enabled. Each PI screen is assigned to a corresponding bit in the PI Screen Register. In order to change PI Screen mask settings the user should select the desired screen using UP and DN buttons and then press RIGHT button. The asterisk will appear/disappear on the right side of the corresponding screen. The asterisk signifies that the screen is enabled. In order to disable the screen, the corresponding asterisk must be removed. Use the ENT button to accept and save new PI Screen Mask settings in the device’s nonvolatile memory.

d) Display Back Light (Numerical entry)

Using Display Back Light settings the user can adjust the desired level of the LCD back light has 19 different levels. Use UP and DN buttons to adjust back light level and press the ENT button to accept and save back light level settings in the device’s nonvolatile memory.

e) Display Contrast (Numerical entry)

Using Display Contrast settings the user can adjust the desired level of the LCD contrast which has 16 different levels. Use UP and DN buttons to adjust contrast levels and press ENT button to accept and save contrast level settings in the device’s nonvolatile memory.

5.3.12 Submenu “Device Function”

This menu selection allows the selection of TIO function according to the mated device type. If TIO is connected to flow meter then

“Meter”

function must be

selected. If TIO is connected to flow controller then

“Controller”

function must be

selected.

NOTE: PI Screen #1 cannot be disabled (unmasked).

NOTE: By default the contrast level is set to 6 which is the optimal level for room temperature (20 °C or 70 °F).

NOTE: The baud rate set on the TIO device should always follow the baud rate of the host PC or PLC it connected to.

5.3.13 Submenu “Communication Settings”

This menu selection allows the configuration of a digital communication interface speed (Baud rate) and device RS-485 bus address (only applicable for optional RS-485 interface)

The following settings are available for “Communication Settings” (see Figure 5.7):

a) Baud Rate Settings (Tabular entry)

This option determines device digital communication interface speed (Baud rate) and can be set to one of the following: 1200

2400 4800 9600 19200 38400 57600 115200

By default the device shipped from factory with baud rate set to 9600.

b) RS-485 Bus Address (Numerical entry)

The standard TIO comes with an RS-232 interface. The optional RS-485 interface has two hexadecimal characters of the address which must be assigned. By default each flow meter is shipped with RS-485 address set to 11 hexadecimal. When more than one device is present on RS-485 bus, each device should have a unique address. The two characters of the address in the hexadecimal representation can be changed from 01 to FF.

NOTE: Based on “Device Function” (device function as flow meter or flow controller) settings, different parameters may be displayed in the Process Information (PI) screen (See Figure 5.4) and different features of the TIO device may be enabled or disabled (set point control only enabled when TIO is configured as flow controller). Also some features (e.g. Flow Alarm) may have different behavior. Be sure the “Device Function” parameter is set according to the actual device being used.

NOTE: Address 00 is reserved for global addressing. Do not assign, the global address for any device. When command with global address is sent, all devices on the RS-485 bus execute the command but do not reply with an acknowledge message.

NOTE: Do not assign the same RS-485 address for two or more devices on the same RS-485 bus. If two or more devices with the same address are connected to the one RS-485 network, a communication collision will take place on the bus and communication errors will occur.

NOTE: Failure to set Full Scale Range parameter in Litr/min equal to the full scale range (converted to Litr/min) of the device mated to TIO may cause an erroneous reading and unexpected device behavior.

RS-485 address setting is not used for TIO’s with RS-232 interface.

5.3.14 Submenu “Device Calibration”

The Calibration Menu contains the parameters, which must be set according to the flow meter / controller being used and according to required process conditions. These values should be changed only by properly trained personnel. Device Analog Output and Input calibration was performed in the factory and should not be initiated unless recommended by factory personnel. The following settings are available for “Device Calibration” menu selection:

a) Full Scale Range (Numerical entry)

The Full Scale Range value in Litr/min should be set equal to the full scale range (converted to Litr/min) of the device mated to TIO. The analog input and output will be scaled automatically to this value. For example, if Full Scale Range value set to 10.0 Litr/min and the device is configured for 0-5 Vdc analog input, when 5.0 Vdc is applied to TIO analog input the PI flow rate will indicate 100.0%FS (if %F.S. units of measure is selected).

b) Low Flow Cut-Off (Numerical entry)

The Low flow cut-off can be selected between 0.0 and 10.0 % of the

full scale range. Flows less than the cut-off value are internally driven to

zero and not totalized. Default value of the “Low flow Cut-Off” parameter is zero (disabled).

c) Flow Power Up Delay (Numerical entry)

Sometimes it is convenient to start the process input signals after the specified power-up delay interval. Most mass flow meters and controllers require some warm-up time from the power-up event in order to stabilize process variable output and get accurate reading. “Flow Power UP Delay” option allows a set specified time interval which must elapse from the device power-up event, before processing of the input signals will be activated. During the active faze of the Power Up Delay, the flow rate will be internally driven to zero and not totalized. Valid settings are in the range of 0 to 3600 seconds (default value is 0, no delay).

d) Fluid Std. Density (Numerical entry)

The density of the flowing fluid at standard temperature and pressure conditions must be entered in g/litr. This parameter is used only when mass-based engineering units are selected. Valid settings are in the range of 0.000001 to 10000.0 g/litr. Factory set default value is 1.25 g/litr (Nitrogen).

e) Analog Output Calibration

The TIO analog output calibration involves calculation and storing the off set and span variables in the EEPROM based on two calibration points (0 and 100% F.S.). The 0-5 (0-10)Vdc output has only scale variable and 4-20 mA output has offset and scale variables.

Power up the TIO instrument for at least 15 minutes prior to commencing the calibration procedure. Observe analog output jumper position (see Figure 4.2) and connect the corresponding type of measurement device to pins 5 (plus) and 8 (minus) of the 9-pin D-connector. Follow firmware prompts and adjust calibration point values according to measurement device reading. If calibration must be aborted, press ESC button. When calibration is completed firmware will display new offset and span values and ask the user to press the ENT button to save new calibration variables to EEPROM or ESC to abort calibration and exit without saving. In the end, the firmware will prompt with confirmation message.

NOTE: The analog outputs available in the TIO were calibrated at the factory. There is no need to perform analog output calibration unless the DAC IC, output amplifier IC or passive components from analog output circuitries were replaced. Any alteration of the analog output scaling variables in the EEPROM table will VOID calibration warranty supplied with the instrument.

f) Analog Input Calibration

NOTE: The analog inputs available for the TIO were calibrated at the factory. There is no need to perform analog input calibration unless the CPU IC, input amplifier IC or passive components from the analog input circuitries were replaced. Any alteration of the analog input scaling variables in the EEPROM table will VOID the calibration warranty supplied with instrument.

NOTE: Check the actual input jumpers’ configuration before applying any input signal to TIO. Be sure your input signal does not exceed the maximum allowed level for corresponding input type (see Table

4.1). Do not apply voltages above 5.0 Vdc unless TIO input was

specifically configured in the factory for 0-10 Vdc (check actual model number and specification). Exceeding maximum allowed input level may cause inadvertent damage to the device circuitry.

The TIO analog output calibration involves calculation and storing the offset and span variables in the EEPROM based on two calibration points (0 and 100% F.S.). The 0-5 (0-10)Vdc output has only scale variable and 420 mA output has offset and scale variables.

Power up the TIO instrument for at least 15 minutes prior to commencing the calibration procedure. Observe analog input jumper position (see Figure 4.2) and connect corresponding type of the calibration signal source device to pins 4 (plus) and 8 (minus) of the 9-pin D-connector. Follow firmware prompts and apply calibration point values according to on screen instructions. If calibration must be aborted, press ESC but ton. When calibration is completed firmware will display new offset and span values and ask press ENT button to save new calibration variables to EEPROM or ESC to abort calibration and exit without saving. In the end, the firmware will prompt with a confirmation message.

g) Pilot Calibration Timer

The Pilot Calibration timer accumulates operational hours since the last time the unit was calibrated. The smallest increment value is 0.1 Hour (6 minutes). The value of the timer may be reset by the user by pressing RIGHT button. Once RIGHT button is pressed the confirmation screen will appear with the “Yes” or “No” menu. Selecting “Yes” will reset the pilot calibration timer back to zero.

5.3.15 Submenu “Signal Conditioner”

A noise reduction filter algorithm (Running Average or Noise Reduction Filter) is available in the flow meter when pulsating flow or especially noisy signals are encountered. The Flow Linearizer algorithm is also available when flow linearity must be improved.

There are three parameters which make up Running Average Filter:

• Number of Samples

• Time Interval

• Error Limit

They are described individually below.

The following settings are available for the “Signal Conditioner” (see Figure 5.7):

a) Signal Conditioner Mode (Tabular Entry)

This option determines whether the Noise Reduction feature is enabled and the type of noise reduction algorithm. The following selections are available: • Disabled

• NRF (Noise Reduction Filter)

• Running Average

Factory default value is NRF.

b) NRF Number of Samples (Numerical Entry)

The sample number value between 1 and 32 can be selected. The number of samples value represents the number of previous individual inputs used to calculate the average value. Eventually the number of samples in the running average also affects the response time. The more samples are used, the more inertial flow output readings will be to the actual flow change. A suggested nominal number of 12 samples (default value) is a good starting point for most applications.

c) NRF Time Interval (Numerical Entry)

Time Interval can be selected between 0 and 199 ms. The value represents the response time of the NRF flow rate change. The higher the Time Interval values the longer the response time of the filter. If noise reduction filter is not desired, it may be disabled by setting the Time Interval parameter to zero. By default units are shipped from the factory with the Time Interval value set to 50.

d) NRF Error Limit (Numerical Entry)

The Error Limit value can be selected between 0.0 and 10.0 % F.S. (for consistency) . The value represents the difference of the signal sample from previous measured value. The Error Limit is configured to reject noise spikes within the flow range while allowing normal variation of the flow signal. The factory default setting 2.0% of full scale optimizes noise rejection in most applications.

e) Average Filter Damping (Numerical Entry)

The Average Filter Damping parameter is only applicable for Running Average mode of the Signal Conditioner and its value can be selected between 0 and 500 ms.The value represents the response time for a 0 - 66 % step flow rate change. When the damping value set to 0, it is disabled. Factory default value is 200.

f) Flow Linearizer Mode (Tabular Entry)

The Flow Linearization algorithm may be used to improve linearity of the flow measurement. The default Flow Linearization Table, stored in the device EEPROM, is linear and does not change input signal. By default the unit is shipped from the factory with disabled Flow Linearizer.

The flow linearization table calibration can be done using only the supplied “TIO Configuration Utility” software via digital (RS-232 or RS-485) interface. It involves building a table of the actual flow values (EEPROM indexes 98, 100, 102, 104, 106, 108, 110, 112, 114, 116, 118) and corresponding sensor readings (EEPROM indexes 99, 101, 103, 105, 107, 109, 111, 113, 115, 117, 119). Actual flow and sensor reading values are entered in normalized fraction format: 100.000 %F.S. corre sponds to 1.000000 flow value 0.000 % F.S. corresponds to 0.000000 flow value. The valid range for flow values is from 0.000000 to 1.000000 (note: TIO will accept up to 6 digits after decimal point). There are 11 elements in the table so the data should be obtained at an increment of

10.0 % of F.S. (0.0, 10.0, 20.0, 30.0, 40.0, 50.0, 60.0, 70.0, 80.0,

90.0 and 100.0 % F.S.).

Note: Do not alter memory index 98 and 99 (must be 0.0). These numbers represent zero flow calibration points and SHOULD NOT BE CHANGED.

5.3.16 Submenu “Program Set Point”

The Program Set Point Control allows execution of custom, user-preset programs of up to sixteen steps. During execution of the program, the user can activate or deactivate the LOOP mode and pause program execution. Various flow configurations may be preprogrammed: ramping, pulsing, linearized increasing and/or decreasing of the flow. Before executing, the program should be entered in the program table in the format: SETPOINT [% F.S.] - TIME [sec.]. TIME means: time it takes for the value of the set point signal for the flow controller, to linearly approach the SETPOINT value (ramping).

Following settings are available for “Program Set Point” (see Figure 5.7):

a) Program Set Point Mode (Tabular Entry)

This function determines whether the Program Set Point is Enabled or Disabled. The following selections are available: Enabled or Disabled. The default entry is Disabled. Program Set Point Mode selections can be set with the UP and DN buttons and are accepted by pressing ENT button.

b) Program Set Point Loop Mode (Tabular Entry)

This function determines whether the Program Set Point Loop is Enabled or Disabled. If Loop is enabled as the program reaches the last step it wraps around and again starts execution from the first enabled step. The following selections are available: Enabled or Disabled. The default entry is Disabled. Program Set Point Loop Mode selections can be set with the

UP and DN buttons and are accepted by pressing ENT button.

c) PSP Steps Mask (Tabular Entry)

Using PSP Steps Mask settings the user can enable (unmask) or disable (mask) any step in the program. If the step is masked, the program will skip it and move to the next enabled step. By default the unit is shipped from the factory with all program steps enabled (unmasked). A typical display with PSP Steps Mask selection is shown below.

Note: Program Set Point feature will work only if “Device Function” parameter is set to Controller.

Note: It is recommended to use Aalborg7 supplied calibration and maintenance software for linearization table calibration. This software includes an automated calibration procedure which may radically simplify reading and writing for the EEPROM linearization table.

In the example shown above, all PSP Steps are enabled. Each PSP Step assigned to a corresponding bit in the PSP Steps Register. In order to change PSP Step mask settings user should select desired Step using UP and DN buttons and then press RIGHT button. The asterisk will appear/ disappear on the right side of the corresponding Step. The asterisk represents that Step is enabled. In order to disable Step, the corresponding asterisk must be removed. Use ENT button to accept and save new PSP Steps mask settings in device non volatile memory.

d) PSP Steps Settings (Numerical Entry)

By using PSP Steps Settings menu selection the user can assign required set point and time values for each step in the program. A typical display with PSP Steps Settings selection is shown below.

In the example shown above, Step 01 is selected. For each step there are two parameters: set point value in %F.S. and time interval in seconds. In order to change PSP Step settings user should select desired step using UP and DN buttons and then press the ENT button. The cursor in the selected (highlighted) parameter will start flashing. Use UP, DN, LEFT, RIGHT buttons to adjust desired value. Then press ENT button to accept and save the new PSP Step settings in the device’s nonvolatile memory.

5.3.17 Submenu “Event Register Menu”

TIO is equipped with a self-diagnostic Alarm Event Register which is available via the digital interface and on the screen LCD indication. Use the “Diagnostic Menu” to navigate to “Event Register Menu” option.

PSP Steps Masc:

S02 0.0% 10s [*] S03 25.0% 25s [*] S04 25.0% 10s [*] S05 50.0% 25s [*]

PSP Steps Settings:

S02 0.0% 10s [*] S03 25.0% 25s [*] S04 25.0% 10s [*] S05 50.0% 25s [*]

S01 0.0% 0s [*]

Table 5.2

EVENT

NUMBER

DIAGNOSTIC AND ALARM EVENTS DESCRIPTION

LCD BIT

CODE

1 CPU Temperature Too High 0

2 High Flow Alarm 1

3 Low Flow Alarm 2

4 Range Between High and Low 3

5 Totalizer#1 Exceed Set Event Volume Limit 4

6 Totalizer#2 Exceed Set Event Volume Limit 5

7 Optical Pulse Output Queue overflow 6

8 Flow Rate above Limit 7

9 Vcc Power Voltage Out of Range 8

10 Serial Communication Error 9

11 EEPROM Error A

12 Power On Event (power on delay timer > 0) B

13 Password Event C

14 Fatal Error (unrecoverable error) D

The following Diagnostic Events are supported:

NOTE: Any Alarm or Diagnostic Events that may have occurred (Event 0 to Event D) are stored in the internal status register. All detected events (if corresponding bit in the latch register is not masked) remain stored until the register is manually reset (by keypad or by means of the digital communication interface). If event corresponding bit in the latch register is masked (disabled), the event will be indicated as long as it is active (no latching). The status Alarm Event Register is mapped to the SRAM (volatile memory). In case of power interruption the status Event Register will be automatically reset.

The following settings are available for “Event Register Menu” (see Figure 5.7):

a) Event Register Status (Read Only)

Each active Alarm Event will be indicated on the LCD screen. In addidtion the total number of currently active events will be displayed on the first line (header). A typical display without active diagnostic and Alarm Events is shown below.

A typical display with two active events is shown below.

If more than 7 events are displayed, the user can use UP and DN buttons to scroll and see all indicated events. If the event is not latched in the Event Latch Mask Register it may appear and disappear from the status screen and will be indicated as long as actual event is taking place.

b) Event Latch Mask (Tabular entry)

Using Event Latch Mask settings the user can enable (unmask) or disable (mask) the latch feature individually for each event. The event is enabled if an asterisk sign [*] is set to the right across from the corresponding event. If the event is not latched (no aste.risk across from the corresponding event) it may appear and disappear from the status screen. It will be indicated as long as the actual event is taking place. By default the unit is shipped from the factory with only one event active: 0 – CPU Temperature Too High. For all other events the latch feature is disabled. A typical display with Event Latch Mask selection is shown below.

Event Reg. Status: 0

No Active Events

Event Reg. Status: 2

2 - Low Flow Alarm

B - Power On Event

Events Latch Mask:

1-Hight Flow Alm. [ ] 2-Low Flow Alm. [ ] 3-Range b/w H-L [ ] 4-Tot#1> Limit [ ]

0-CPU Temp. High [*]

In the example shown above, latch features for all events are disabled, except event #0. In order to change Event Latch mask settings, the user should select the desired event using UP and DN buttons and then press the RIGHT button. The asterisk will appear/disappear on the right side of the corresponding event. The asterisk represents that the latch feature is enabled. In order to disable latch feature, the corresponding asterisk must be removed. Use ENT button to accept and save new Event Latch mask settings in the device’s non-volatile memory.

c) Event Register Mask (Tabular entry)

Using the Event Register Mask settings, the user can individually enable (unmask) or disable (mask) each event. The event is enabled if the asterisk sign [*] is set to the right across from corresponding event. If the event is disabled, it will not be processed and indicated in the Events status Register even actual conditions for the event have occurred. By default the unit is shipped from the factory with only one event active: “0 – CPU Temperature Too High”. All other events are disabled. A typical display with Event Register Mask selection is shown below.

Events Latch Mask:

1-Hight Flow Alm. [ ] 2-Low Flow Alm. [ ] 3-Range b/w H-L [ ] 4-Tot#1> Limit [ ]

In the example shown above, all events are disabled, except event #0. In order to change Event Register mask settings user should select the desired event using UP and DN buttons and then press the RIGHT button. The asterisk will appear/disappear on the right side of the corresponding event. The asterisk represents that the event is enabled. In order to disable event, the corresponding asterisk must be removed. Use the ENT button to accept and save the new Event Register mask settings in the device’s nonvolatile memory.

0-CPU Temp. High [*]

5.3.18 Submenu “Diagnostic Menu”

The Diagnostics Menu can be used for troubleshooting purposes and provides information about the device’s internal variables. These items (except Events Register submenu described above) are only informational and cannot be changed (read only).

a) ADC Input Counts (Read Only)

This menu selection provides raw, average, and filtered values of the ADC counts for analog input circuitry (read only). A typical display with ADC Input Counts screen is shown below.

b) Analog Output Values (Read Only)

This menu selection provides information about currently selected analog output configuration, and DAC counts for analog output circuitry (read only). A typical display with DAC Output Values screen is shown below.

* ADC Input Counts*

Raw: 3 1221 A: 4 1225 NRF: 4 1226

**********************

Event Reg. Has been reset!

Press any key...

Reset Event Reg.:

YES

DO YOU WANT

RESET EVENT REG?

Once the “YES” option is selected, the Event Register will be reset and the following conformation screen will appear.

d) Reset Event Register (Tabular entry)

The Event Register can be reset by selecting “Reset Event Register” menu option. A typical display with Reset Event Register screen is shown below.

LCD Back Light Set:

TIM3_CCR1:12 Duty Cycle: 60% Contrast: 6

Pulse Output Queue:

PO Queue: 0

Max Limit: 250

d) Pulse Output Queue (Read Only)

This menu selection provides information about Pulse output queue. A typical display with Pulse Output Queue screen is shown below.

e) CPU Temperature (Read Only)

This menu selection provides the current value of the PCB and CPU temperature in °C (read only). A typical display with CPU Temperature reading is shown below.

CPU Temperature:

35.8 C

Analog Output Value:

Output Conf: 0-5 Vdc DAC Update: Enabled DAC Counts: 0

c) LCD Back Light Settings (Read Only)

This menu selection provides information about LCD back light level, PWM duty cycle and contrast (read only). A typical display with LCD Back Light Settings screen is shown below.

6. INSTALLATION

6.1 General Directions

• Mounting, electrical installations, parameters configuration, start up, and maintenance of this instrument may only be performed by trained personnel. Personnel must read and understand this operating manual before performing any installation or configuration steps.

• The TIO device should only be operated by trained personnel. All instructions in this manual are to be observed.

• Ensure that power and all input / output signals are correctly wired according to the wiring diagram provided in this manual. The housing of the device should only be opened by trained personnel.

6.2 Hardware Installation

NOTE: Electrostatic discharge may cause permanent damage to the electronic circuitry. Before installing or connecting any wires, the installer must discharge himself by touching the building protective earth ground.

The TIO Totalizer Input / Output Flow monitor / Controller can be attached (mounted) to the Aalborg7 GFM series flow meters, GFC series controllers or used stand alone (panel mounted or table top installation).

Figure 6.1 Mounting TIO to the GFM Flow Meter

b) Electrical Connection

GFM Flow Meters have three different output interfaces (0-5, 5-10 Vdc, 4-20 mA) which can be used to provide flow input signal to TIO.

6.2.1 Connecting TIO to GFM series Flow Meter

a) Mounting

Use GFM mounting kit (See Table 5.1) to attach TIO to the GFM Flow Meter (see Figure 6.1).

Figure 6.2 Connecting TIO to the GFM using 0-5 Vdc output from DB9 connector.

Figure 6.3 Connecting TIO to the GFM using 5-10 Vdc output from RJ11 connector.

Figure 6.4 Connecting TIO to the GFM using 4-20 mA output from DB9 connector.

Based on interface being used, Optional Cables Kit Assemblies are available for order. See Table 6.1 for optional GFM cables kit assemblies.

c) Input/Output Jumper Configuration

TABLE 6.1 OPTIONAL GFM CABLES AND MOUNTING KIT ASSEMBLIES

Kit Part

Number

DESCRIPTION

TIO

Input

Communication

Interface Cable

GFM Power

Supply Option

KIT-TM-

Shielded cable with two 9 pins D-connectors for process signals and 6 feet

communication branch

0-5 Vdc

YES 12 and 24 Vdc

KIT-TM-RD4 wires cable between GFM RJ11 and

TIO 9 pin D-connector

5-10

Vdc

NO 12 Vdc only

KIT-TM-FDFlat 4 wires cable between GFM and

TIO 9 pin D-connectors

0-5 Vdc

NO 12 and 24 Vdc

KIT-TM

GFM flow meter mounting kit,

no cables

N/A N/A N/A

NOTE: For all GFM Kits (except KIT-TM) it is assumed that the power supplied is connected to the GFM power DC jack connector and the TIO receiving the power from the GFM.

NOTE: Your TIO device input / output jumpers were configured at the factory according to your order. There is no need to change input / output jumpers’ configuration unless a different input is being used. Before applying power and process signals, make sure the input /output jumpers are installed in the correct position (See Table 6.2).

TABLE 6.2 J2 INPUT / OUTPUT JUMPER CONFIGURATION OPTIONS

FOR GFM SERIES FLOW METERS

PV INPUT

TYPE

(TIO INPUT)

J2 JUMPER CONFIGURATION

GFM

CABLE KIT

NOTE

J2A J2B J2C J2D J2E J2F

0 - 5 Vdc 2 - 3 5 - 6 8 - 9 10-11 14-15 17-18

KIT-TM-DD

KIT-TM-FD

5 - 10 Vdc 2 - 3 5 - 6 8 - 9 11-12 14-15 17-18 KIT-TM-RD

+5Vdc

reference

signal must

be used

0 - 10 Vdc 2 - 3 5 - 6 8 - 9 11-12 14-15 17-18

NOT

SUPPORTED

FOR GFM

Special Order

option! (PCB

hardware must

be changed)

4 – 20 mA 2 - 3 5 - 6 8 - 9 10-11 13-14 16-17

N/A (user

custom cable

assembly)

(249 Ohm

passive, not

isolated current

input)

d) Parameters Configuration

Following parameters must be configured:

• Device Function (See 4.3.12 Submenu “Device Function”). “Meter”

function must be selected.

• Full Scale Range (See 4.3.14 Submenu “Device Calibration”). Full

Scale Range parameter must be set equal to the GFM full scale flow rate in Litr/min.

• Fluid Std. Density (See 4.3.14 Submenu “Device Calibration”). This

parameter is required only when mass-based engineering units are selected.

User may configure other parameters (see Paragraph 5.3) according to individual preferences and application requirements.

NOTE: If “Full Scale Range”, “Device Function” and “Fluid Std. Density” parameters are not set properly the device may have erroneous reading and unpredictable behavior.

6.2.2 Connecting TIO to GFC series flow controller

a) Mounting

Use GFC Mounting Kit (See Table 6.3) to attach TIO to the GFC flow controller (see Figure 5.5).

Figure 6.5 Mounting TIO to the GFC Flow Controller

b) Electrical Connection

GFC flow controllers have two output interfaces: 0-5 Vdc and 4-20 mA which can be used to provide flow input signal to TIO. They also support two analog input signals: 0-5Vdc and 4-20 mA (jumper-selectable on the GFC PC board).

Figure 6.6 Connecting TIO to the GFC Using 0-5Vdc Input / Output from DB15 Connector.

Figure 6.7 Connecting TIO to the GFC Using 4-20mA Input / Output from DB15 Connector.

Based on interface being used and power supply option, optional Cables Kit Assemblies are available for order. See Table 6.3 for optional GFC Cables Kit Assemblies.

TABLE 6.3 OPTIONAL GFC POWER SUPPLY / CABLES AND MOUNTING

KIT ASSEMBLIES

Kit Part

Number

Description

TIO

Input/Output

Communication

Interface Cable

GFC Power

Supply Option

KIT-TC-

110NA-2C

Shielded cable with North

America plug 110 Vac to 12

Vdc power supply,

communication branch

0-5 Vdc YES 12 Vdc only

KIT-TC-

110NA-2N

Shielded cable with North

America plug 110 Vac to 12

Vdc power supply

0-5 Vdc NO 12 Vdc only

KIT-TC-

110NA-4C

Shielded cable with North

America plug 110 Vac to 24

Vdc power supply,

communication branch

0-5 Vdc YES 24 Vdc only

KIT-TC-

110NA-4N

Shielded cable with North

America plug 110 Vac to 24

Vdc power supply

0-5 Vdc NO 24 Vdc only

KIT-TC-

230EU-2C

Shielded cable with

EUROPE plug 230 Vac to

12 Vdc power supply,

communication branch

0-5 Vdc YES 12 Vdc only

KIT-TC-

230EU -2N

Shielded cable with

EUROPE plug 230 Vac to

12 Vdc power supply,

communication branch

0-5 Vdc NO 12 Vdc only

KIT-TC-

230EU-4C

Shielded cable with

EUROPE plug 230 Vac to

24 Vdc power supply,

communication branch

0-5 Vdc YES 24 Vdc only

KIT-TC-

230EU-4N

Shielded cable with

EUROPE plug 230 Vac to

24 Vdc power supply,

communication branch

0-5 Vdc NO 24 Vdc only

KIT-TC-

240AU-2C

Shielded cable with

AUSTRALIA plug 240 Vac

to 12 Vdc power supply,

communication branch

0-5 Vdc YES 12 Vdc only

Kit Part

Number

Description

TIO

Input/Output

Communication

Interface Cable

GFC Power

Supply Option

KIT-TC-

240AU-2N

Shielded cable with

AUSTRALIA plug 240 Vac

to 12 Vdc power supply

0-5 Vdc NO 12 Vdc only

KIT-TC-

240AU-4C

Shielded cable with

AUSTRALIA plug 240 Vac

to 24 Vdc power supply,

communication branch

0-5 Vdc YES 24 Vdc only

KIT-TC-

240AU-4N

Shielded cable with

AUSTRALIA plug 240 Vac

to 24 Vdc power supply

0-5 Vdc NO 24 Vdc only

KIT-TC-

240UK-2C

Shielded cable with UK plug

240 Vac to 12 Vdc power

supply, communication

branch

0-5 Vdc YES 12 Vdc only

KIT-TC-

240UK -

Shielded cable with UK plug

240 Vac to 12 Vdc power

supply

0-5 Vdc NO 12 Vdc only

KIT-TC-

240UK -4C

Shielded cable with UK plug

240 Vac to 24 Vdc power

supply, communication

branch

0-5 Vdc YES 24 Vdc only

KIT-TC-

240UK-4N

Shielded cable with UK plug

240 Vac to 24 Vdc power

supply

0-5 Vdc NO 24 Vdc only

KIT-TC

GFC flow controller

mounting kit, no cables, no

power supply

N/A N/A N/A

NOTE: All GFC Kits (except KIT-TC) have power supply for GFC flow controller and TIO receiving the power from GFC.

c) Input/Output Jumper Configuration

NOTE: Your TIO device input / output jumpers were configured at the factory according to your order. There is no need to change the input / output jumper’s configuration unless different input is being used. Before applying power and process signals make sure the input / output jumpers are installed in the correct position (See Table 6.4).

TABLE 6.4 J2 INPUT / OUTPUT JUMPER CONFIGURATION OPTIONS FOR GFC SERIES

FLOW CONTROLLERS

TIO PV TYPE J2 JUMPER CONFIGURATION

GFC

CABLE KIT

NOTE

OUTPUT INPUT J2A J2B J2C J2D J2E J2F

0-5Vdc 0-5Vdc 2 - 3 5 - 6 8 - 9 10-11 14-15 17-18

KIT-TC-

XXXXX-XX

Supported by

all GFC Kits,

except KIT-TC

0-5Vdc

4-20

2 - 3 5 - 6 8 - 9 10-11 13-14 16-17

N/A (user

custom

cable

assembly

only)

Not supported by GFC Cable

Kits

4 – 20

0-5Vdc 1 - 2 4 - 5 7 - 8 10-11 14-15 17-18

N/A (user

custom

cable

assembly

only)

Not supported by GFC Cable

Kits

4 – 20mA4 – 20

1 - 2 4 - 5 7 - 8 10-11 13-14 16-17

N/A (user

custom

cable

assembly

only)

Not supported by GFC Cable

Kits

0 - 10

Vdc

0 - 10

Vdc

2 - 3 5 - 6 8 - 9 11-12 14-15 17-18

NOT

SUPPORTED

BY GFC

Special Order

option! (PCB

hardware

must be

changed)

d) Parameters configuration

The following parameters must be configured:

• Device Function (See 5.3.12 Submenu “Device Function”).

“Controller”

function must be selected.

• Full Scale Range (See 5.3.14 Submenu “Device Calibration”). Full

Scale Range parameter must be set equal to the GFC full scale flow rate in Litr/min.

• Fluid Std. Density (See 5.3.14 Submenu “Device Calibration”). This

parameter is required only when mass-based engineering units are selected.

User may configure other parameters (see Paragraph 5.3) according to his preferences and application requirements.

6.2.3 Connecting TIO to flow meters/controllers

from other manufactures (stand alone)

a) Mounting

When TIO is connected to flow meters / controllers from other manufactures, it can be used as stand-alone table top or panel- mounted (see Figure 6.8). On the back side of the TIO enclosure there are 4 tapped holes which are designated to be used for the panelmounted option.

NOTE: If “Full Scale Range”, “Device Function” and “Fluid Std. Density” parameters are not set properly, the device may have erroneous reading and unpredictable behavior.

Figure 6.8 Dimensions for Panel Mounted Installation

b) Electrical Connection

TIO can be used with any generic flow meter / controller which supports 0-5 Vdc and / or 4-20 mA input / output interfaces. It also can be ordered for 0-10 Vdc input / output interface (special order not supported by generic models).

NOTE: Do not connect TIO input / output circuitry to voltages above

5.5Vdc unless TIO was specifically ordered for 0-10 Vdc input / output interface. Check device part number or contact Aalborg 7 customer service for device input / output type verification.

Panel Mounting

Figure 6.9 Connecting TIO to the Generic Flow Meter

Figure 6.10 Connecting TIO to the

Generic Flow Controller

TABLE 6.5 J2 INPUT / OUTPUT JUMPER CONFIGURATION OPTIONS FOR GENERIC

FLOW METERS AND CONTROLLERS

TIO PV TYPE J2 JUMPER CONFIGURATION

NOTE

Output Input J2A J2B J2C J2D J2E J2F

0-5Vdc 0-5Vdc 2 - 3 5 - 6 8 - 9 10-11 14-15 17-18

0-5Vdc

4-20

2 - 3 5 - 6 8 - 9 10-11 13-14 16-17

4 – 20

0-5Vdc 1 - 2 4 - 5 7 - 8 10-11 14-15 17-18

4 – 20mA4 – 20

1 - 2 4 - 5 7 - 8 10-11 13-14 16-17

N/A

5-10

Vdc

2 - 3 5 - 6 8 - 9 11-12 14-15 17-18

External +5Vdc

reference signal must

be connected to pin 9

0 - 10

Vdc

0 - 10

Vdc

2 - 3 5 - 6 8 - 9 11-12 14-15 17-18

Special Order option!

(PCB hardware must be

changed)

0 - 10

Vdc

4 – 20

2 - 3 5 - 6 8 - 9 10-11 13-14 16-17

Special Order option!

(PCB hardware must be

changed)

4 – 20mA0 - 10

Vdc

1 - 2 4 - 5 7 - 8 11-12 14-15 17-18

Special Order option!

(PCB hardware must be

changed)

0-5Vdc

0 - 10

Vdc

2 - 3 5 - 6 8 - 9 11-12 14-15 17-18

Special Order option!

(PCB hardware must be

changed)

0 - 10

0-5Vdc 2 - 3 5 - 6 8 - 9 10-11 14-15 17-18

Special Order option!

(PCB hardware must be

changed)

NOTE: Your TIO device input / output jumpers were configured at the factory according to your order. There is no need to change input / output jumper’s configuration unless different input is being used. Before applying power and process signals, make sure the input /out put jumpers are installed in the correct position (See Table 6.5).

c) Input/Output Jumper Configuration

d) Parameters configuration

Following parameters must be configured:

• Device Function (See 5.3.12 Submenu “Device Function”). If TIO is connected

to flow controller, then

“Controller”

function must be selected. If TIO is

connected to flow meter, then

“Meter”

function must be selected.

• Full Scale Range (See 5.3.14 Submenu “Device Calibration”). Full

Scale Range parameter must be set equal to the mated device full scale flow rate in Litr/min.

• Fluid Std. Density (See 5.3.14 Submenu “Device Calibration”). This

parameter is required only when mass-based engineering units are selected.

User may configure other parameters (see Paragraph 5.3) according to individual preferences and application requirements.

7. TROUBLESHOOTING

7.1 Common Conditions

Your TIO Totalizer Input/Output Flow Monitor/Controller was thoroughly checked at numerous quality control points during and after manufacturing and assembly operations. It was calibrated according to your input and output configuration. It was carefully packed to prevent damage during shipment. Should you feel that the instrument is not functioning properly, please first check for the following common conditions:

• Are all cables connected correctly?

• Are the connector pin outs matched properly?

• Are J2 input / output jumpers configured correctly?

• Is the power supply correctly selected according to requirements?

NOTE: When TIO is connected to flow meter, output circuitry is not used. Jumpers J2A, J2B, J2C configuration is not applicable in this case and they should not be changed. In order to disable analog output, jumper J2B must be removed.

NOTE: If “Full Scale Range”, “Device Function” and “Fluid Std. Density” parameters not set properly, device may have erroneous reading and unpredictable behavior.

When several devices are used a power supply with appropriate current rating should be selected. When interchanging with other manufacturers' equipment, cables and connectors must be carefully wired for correct pin configuration.

7.2 Troubleshooting Guide

NO. INDICATION LIKELY REASON SOLUTION

LCD Display remains blank when unit is powered up. Status LED is OFF

Power supply is bad or polarity is reversed.

Measure voltage on pins 2 and 1 of the DB9 interface terminal connector. If voltage is out of specified range, then replace power supply with a new one. If polarity is reversed (reading is negative) make correct connection.

PC board is defective. Return device to factory for repair.

LCD Displays flow reading, but 4-20 mA set point output signal does not change

Wrong configuration of J2 Input/Output Jumpers

Check J2 jumper configuration (see Table

6.4)

External loop is open or load resistance more than 600 Ohm.

Check external connections to pins 5 and 6 of the DB9 interface terminal connector. Make sure the loop resistance is less than 400 Ohm for 12Vdc power supply option and 900 Ohm for 24Vdc power supply option.

4-20 mA circuitry is burned out or damaged.

Using Key Pad, navigate to Submenu “ Device Diagnostic” and select submenu “Analog Output Value”. Record the DAC counts values and consult the factory with findings.

Fluid flows through the flow meter / controller, but LCD Display and /or Totalizer reading do not respond to the flow.

The fluid flow rate is below set Low flow cutoff value.

Check settings for Low Flow Cut-Off value and make required adjustment (see paragraph 5.3.14 submenu “Low Flow Cut Off”).

Wrong configuration of J2 Input/Output Jumpers

Check J2 input jumper configuration (see Table 6.4) If necessary contact factory for additional help.

PC board is defective. Using ESD precautions, measure voltage on

pins 4 and 6 of the DB9 interface terminal connector. If voltage correlates with flow meter / controller output signal, check ADC counts: using Key Pad, navigate to Submenu “Device Diagnostic” and select submenu “ADC Input Counts”. Record the ADC counts values and consult the factory with findings.

Fluid flows through the flow meter / controller, LCD Display Flow Rate reading responds to flow, but Totalizer reading is not changing.

The fluid flow rate is below set “Totalizer #1 Flow Start” parameter value.

Check settings for “Totalizer #1 Flow Start” value and make required adjustment (see paragraph 5.3.7.b submenu “Totalizer #1 Flow Start”).

Totalizer mode is disabled

Check settings for “Totalizer #1 Mode” parameter. Make sure Totalizer Mode set to “Enabled” (see paragraph 5.3.7.a submenu “Totalizer #1 Mode”).

Totalizer Power On Delay parameter is set to high value and Totalizer is disabled by firmware.

Check settings for “Totalizer Power On Delay” (see paragraph 5.3.7.e submenu “Totalizer #1 Power On Delay”). If settings

are too high, make required adjustment.

NO. INDICATION LIKELY REASON SOLUTION

Erratic Flow rate Reading

Wrong configuration of J2 Input/Output Jumpers

Check J2 input jumper configuration (see Table 6.4) If necessary contact factory for additional help.

TIO “Full Scale Flow” parameter value (in litr/min) is not equal to the mated device full scale range

Check settings for “Full Scale Range (See Paragraph 5.3.14 Submenu “Device Calibration”). Full Scale Range parameter must be set equal to the mated device full scale flow rate in Litr/min.

TIO “Fluid Std. Density” parameter is not set according to fluid being used and mass-based engineering units are selected.

Check settings for “Fluid Std. Density” (See Paragraph 5.3.14 Submenu “Device Calibration”). This parameter is required only when mass-based engineering units are selected.

Totalizer reading is wrong

Wrong configuration of J2 Input/Output Jumpers

Check J2 input jumper configuration (see Table 6.4) If necessary contact factory for additional help.

TIO “Full Scale Flow” parameter value (in litr/min) is not equal to the mated device full scale range

Check settings for “Full Scale Range (See Paragraph 5.3.14 Submenu “Device Calibration”). Full Scale Range parameter must be set equal to the mated device full scale flow rate in litr/min.

LCD Displays flow reading, but communication interface does not work.

Wrong host PC interface, or wiring connection.

Make sure interface type (RS-232 or RS-

485) on the host PC is the same as on TIO device. If required, use RS-232 to RS-485 converter. Check communication wiring connection according to Paragraph 4.4

TIO has RS-485 interface, butt device address does not match to address used by host PC.

Change TIO RS-485 address to be matched to host PC software settings (see Paragraph

5.3.13 b).

The Device Diagnostic Alarm Event with code 0 – “CPU Temp. High” is active.

MCU / PCB temperature is too high (overload).

Disconnect power from the TIO. Make sure the ambient temperature is within specified range (below 70 °C). Let the device cool down for at least 15 minutes. Apply power to the device and check Diagnostic Alarm Event. If overload condition will be indicated again the unit must be returned to the factory for repair.

The Device System Event with code D “Fatal Error” is active.

Fatal Error (EEPROM or SRAM corrupted)

Cycle the power on the TIO. If System Event with code D indication again the unit must be returned to the factory for repair.

INDEX NAME DATA TYPE NOTES

BlankEEPROM[10]

char[10]

Do not modify. Table Revision [PROTECTED]

SerialNumber[20]

char[20]

Serial Number [PROTECTED]

ModelNumber[20]

char[20]

Model Number [PROTECTED]

SoftwareVer[10]

char[10]

Firmware Version [PROTECTED]

ManufReservedF1

float